Effect of Printing Parameters on Mechanical Properties, Warpage of 3D Printed PEEK/CF-PEEKComposites Using Multi-Objective Optimization Technique

Polyetheretherketone (PEEK) is a high-performance thermoplastic widely used in aerospace, automotive, and medical applications due to its exceptional strength, heat resistance, and chemical stability. However, warpage and mechanical property variations remain significant challenges in 3D printing PEEK parts. This study investigates the effect of key printing parameters, including nozzle temperature, layer thickness, platform temperature, and infill rate, on the mechanical properties and warpage of 3D-printed PEEK components. By systematically analyzing tensile and compressive loading conditions, this research aims to optimize printing settings to improve dimensional accuracy and structural integrity. Experimental results indicate that mechanical properties, such as tensile and compressive stress at break, vary significantly with printing conditions. The highest tensile strength of 71.4 MPa and compressive strength of 167 MPa were achieve. Meanwhile, lower tensile (45.36 MPa) and compressive strengths (72.5 MPa) were recorded. Higher nozzle and platform temperatures, coupled with increased infill rates, enhance layer adhesion, leading to improved tensile and compressive strength. However, with a nozzle temperature of 400°C, platform temperature of 130°C, and 60% infill rate, demonstrating optimal bonding between layers and leads to reduction in warpage. Considering warpage in all four corners and mechanical properties, 400°C nozzle temperature, 0.16 layer thickness, 130°C platform temperatures, coupled with 60% infill rates, shows optimal printing conditions. The 10% carbon fiber-reinforced PEEK composites exhibit improved tensile strength 1.68 times compared to pure PEEK. To emphasize the importance of thermal and structural settings, the findings highlight the crucial role of printing parameters in minimizing warpage and enhancing mechanical properties in 3D-printed PEEK parts that is analyzed by muti multi-objective optimization method. The Scanning Electron Microscopy Analysis were carried out to analyze the fracture morphology and printing layers orientation.