Polyether ether Ketone (PEEK) and Polyetherimide (PEI) blends for 3D printed medical devices

Additive manufacturing or 3D printing has gained significant traction in recent years, establishing itself as an alternative manufacturing technique across a multitude of industries, including automotive, aerospace and medical industries. Polyether ether Ketone(PEEK) and Polyetherimide (PEI) are 2 high performance polymers which exhibit excellent mechanical, chemical, and thermal properties individually. In order to benefit from the combined properties associated with each polymer an extrusion process has been utilized to blend the 2 polymers in a series of ratio blends, producing filament for fused filament fabrication (FFF). Through the creation of this composite material, this work aims to identify an optimum ratio blend by characterizing the materials thermal properties and crystallinity by Differential Scanning Calorimetry (DSC), X-ray Diffraction (XRD) and Thermogravimetric Analysis (TGA). Further testing will be carried out on samples produced using each blend, to assess the mechanical properties. Initial testing and results indicate that the blend does not massively compromise the tensile strength of the neat materials, and in the 50:50 blend, enhances it, however crystallinity levels have been decreased. The results of further testing will allow for the selection of a PEEK/PEI blend which will be suitable for medical applications, displaying biocompatibility, strength, as well as thermal and chemical resistance. The integration of this material into FFF will allow for the customization and design of patient specific medical devices.