poly ether ether ketone Archives - Perfect 3D Printing Filament

PEEK polyether ether ketone is a high-performance thermoplastic with high continuous service temperatures, strength, and low flame smoke and toxicity. Due to this, it is an oft sought material by engineers in applications such as automotive under the hood parts or aerospace parts. But, PEEK is considered to be a wonder material by many not just because it meets a lot of high tech engineering requirements. One can also use PEEK in the body for implants. Several spinal screws, suture anchors, orthopedic implants, and other long term in the body implant products have come to the market recently and in things as diverse as CMF and spine, PEEK is in high demand.

Generally, PEEK implants are made through CNC or if they are printed they are made with SLS (powder bed fusion, sintering). SLS is a tried and true technology that has won approvals for surgical guides and implants. SLS’s high productivity, reliability, and predictability make it a good technology to manufacture things with, especially if they are small and require precision. SLS PEEK powders are expensive however. With SLS a laser, sinters some lose polymer powder on a bed of spread out powder. A new layer is then spread out and the process repeats itself. Unsintered powder acts as a support material and once a big block or cake has been built this is removed from the printer and parts are sieved out and brushed out to remove the loose powder. This remaining powder can then to a certain extent be mixed in with new virgin powder and used again. The recycling rate depends on the powder and the build.

Essentially, if a printer uses a metric tonne of powder a month we end up recycling a third per build and ultimately end up throwing away half a tonne of powder for every 500 Kg’s of built parts. Nota Bene: this is just a general example meant to make people understand the economics of SLS a bit better, with different materials and parts, spot, spacing etc. you’ll get different results. This is still way more efficient than cutting away material for CNC for example, but is quite a waste. If you’re paying $100 a kilo for PA, then this is quite expensive on a monthly basis. And this is for a medium machine working at full production. $50,000 per machine per month, ouch. Imagine you’ve got ten or more.

But, PEEK powder is way way more expensive than that. You’ll be paying five to nine times more per Kilo for PEEK depending on the certification. And it gets worse, because the recycling rate of PEEK powder in SLS machines is effectively 0. We toss out all of it. All of it. Everything that is not a built part is thrown away. So depending on the utilization, specific grade, and machine; you’re tossing out a pair of Ferrari’s per month in powder, per machine. Imagine you’re an entrepreneur with your own service bureau and you walk by some bins every day with 4 911’s worth of powder in them, that you will then toss out that day, that’s got to hurt.

This explains the rationale for Evonik’s launch today of a PEEK Filament for implants. 3D4Makers, 3DXtech, Appium, and other firms have offered PEEK filament for a number of years now. Solvay has a healthcare grade PEEK filament that you can buy as well which is ISO 10993 and suitable for limited contact applications for 24 hours and less. PEEK leader Victrex has sold medical PEEK for implantology to a select few also. Alternative materials such as PEKK from Arkema are available but often not with the certifications and approvals to use long term in the body. Now Evonik has an FDM grade suitable for implants specifically.

Polymer companies are reticent to allow for the use of polymers in the body long term because of the suitability of the material for that purpose and also legal liability. DowCorning a huge joint venture went bankrupt over liability related to breast implants that “never represented more than 1 percent of our business” and yet forced the company to set aside $2.35 billion for claimants. Many polymer firms, therefore, consider possible medical implant polymer revenue not sufficient for a possible headshot for their firm.

In this case, Evonik has done its homework on its ASTM F2026 compliant PEEK filament. The business case is clear, with FDM you print only the material that you use (plus extra possible support). This means that you will end up using a lot less material per part than if you fill a full SLS machine. Especially with larger implants, FDM does have an advantage in time in the machine and time to part as well. Besides Kumovis and Vshaper, there has been little development of medical part-specific high-temperature printers for FDM. I think that this can be a fantastically profitable niche that would be difficult from which to dislodge a reliable supplier from. Evonik’s launch of this FDM material can serve as an impetus for the development of more medially capable high-temperature FDM printers that one would need in order to use the filament.

With a surgical implant PEEK material the VESTAKEEP i4 3DF, 1.75 mm, on 250 or 500 gram spools is based on VESTAKEEP i4 G with good “biocompatibility, biostability, x-ray transparency, and easy handling.” X-Ray transparency is a great advantage of polymer medical implants since it allows doctors to check if the implant is placed correctly after implantation and lets them do CT scans especially those with contrast die, after or even during implantation or scans which can let them adequately see bone or tissue healing progress. In CT’s and MRI’s metal implants cause artefacts on some scans, or may block surgeons from seeing important details through shadows or opacity. Magnetic implants and MRI’s are also not an awesome combo.

Marc Knebel, of Evonik Medical Devices & Systems,

“For modern medical technology, the development of our first 3D-printable implant material opens up new opportunities for customizing patient treatments. Orthopedics and maxillofacial surgery are examples of areas where this could be applied. Innovative high-performance materials like Evonik’s VESTAKEEP PEEK—along with highly complex hardware and software, and the perfect match between materials and machines—form the basis for a sustainable 3D-printing revolution in medical technology. Therefore, we will successively expand our product portfolio of 3D printable biomaterials.”

In order to make you less gun shy on taking the leap for PEEK Evonik has released a testing grade,

“The term refers to a class of material having the exact same product properties as the implant grade, but without the documentation needed for approval in medical technology applications. This offers a cost-effective way of adapting the processing characteristics of the high-performance plastic to a given 3D printer.”

This is a great idea that other companies should look into adopting as well as it would make research and product development into high-performance polymers much more cost-effective.

The post Evonik Launches FDM PEEK Filament for Implants appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Additive manufacturing is changing the world. Another term for 3D printing, additive manufacturing differs from other forms of manufacturing in that, rather than removing material like machining, it adds material to create a product. This offers many unique advantages, from unprecedented customization and precision to a whole new world of shapes that are not possible with other techniques.

3D printing works by providing a carefully planned CAD file to a computer that runs a 3D printer. This machine prints the material layer by layer. There are a variety of materials and methods for 3D printing. You can 3D print plastic, nylon, metal, and more. Products can be printed through traditional 3D printing or through more specialized processes like selective laser sintering (SLS) or multi jet fusion (MJF), where there is no need for support structures to print complex designs. Between the design, material, and the process, no additive manufacturing job is quite alike.

These factors allow for some incredible customization of designs. You don’t have to modify an existing template or object. Additive manufacturing allows for strangely shaped spaces and corners. Weight can be more easily managed thanks to this kind of customization and the wide range of available materials. Some designs are incredibly delicate yet smooth. There is no need for support structures for these designs, allowing a lot of creative freedom that wasn’t previously available once you got off the drawing board.

Additive manufacturing already sees a lot of use. There are plenty of hobbyists out there, certainly, but it’s also being used by businesses to do things like produce prototypes or even their main product from custom parts for almost anything to modeling kits. Companies such as HP and Honeywell are developing 3D printing technology as we speak. They’re looking to improve quality and efficiency as well as allow for a new range of materials to be printed. These are not pie-in-the-sky ideas, but real developments that are already making a mark.

This is because a company has a lot to gain from switching from traditional manufacturing techniques to additive manufacturing. 3D printing is a great way to save money. The ability to reduce weight can be a major factor, especially if you are looking to make parts. It’s possible to create hollow or honeycomb-structured parts that are just as strong and capable as solid ones, but much lighter.

You can also order to demand. other manufacturing techniques may require you to order a minimum number of products that is much larger than what you actually need. This is because there is a much larger start-up cost to these techniques for a product line and the company needs to make a profit, not a loss, on your order. Additive manufacturing does not work this way. You can order three or three-hundred products, whatever you need. The cost of an order largely comes from the material that needs to be used to make it.

This makes 3D printing an excellent choice if you do not need a massive, expensive order. The quality will still be high, but the price will be much lower and you won’t be stuck with stock you can’t sell, taking up room that can be better used for other things.

Additive manufacturing is less wasteful, too. Traditional manufacturing techniques are messy and leave a lot of scraps behind. Not so with additive manufacturing. It’s far more efficient with material. What scraps are produced are often recycled, melted back down to be used for more 3D printing. You are only charged for the material that is actually used to create the product(s), not what’s used plus the scraps that end up on the shop floor.

This incredible and increasing cost efficiency of 3D printing means additive manufacturing making waves in manufacturing. It’s not just for custom phone cases and graduate student research projects anymore. More and more businesses are choosing to use 3D printing to make their products. This has prompted new technological developments as the possibilities of 3D printing have been explored.

Check out these major developments in 3D printing for 2019 (which is only half over!):

HP just opened its 3D Printing and Digital Manufacturing Center of Excellence in Barcelona, Spain. HP has been on the leading edge of 3D printer development. HP has just released new materials like Nylon 11 and TPU (a material that is highly flexible like rubber). This facility is a center for testing and collaboration between industry experts and customers alike. Expect to see a lot of additive manufacturing news to come out of here.

Photocentric introduced its Liquid Crystal (LC) Magna system. This is their second largest LCD printer.This new 3D printer is 10 times faster than its predecessor. It has 23.8 inch 4K Ultra HD screen with a custom backlight. These allow for an average print accuracy of within 50 µm and model tolerances of less than 100µm. It takes only a few hours to produce batches of custom products.

Autodesk, one of the major players in the additive manufacturing software world, released new add-ons for its 3D modeling software Fusion 360. This entry-level platform now provides cost-estimation and generative design. It’s a popular choice for those looking to start getting into 3D printing design and it is now an even better choice.

EOS and ALM have just released HT-23, a new PEKK carbon fiber material that is a high-performance polymer that is extremely chemically resistant, has a high melt point, and is inherently flame retardant.

At Jawstec, we are ready to help your business take advantage of 3D printing. We keep track of the latest developments in the industry and our experts can leverage them to help you create the product you want. Whether you’re looking to produce a prototype or a whole product line, our 3D printing services offer an efficient, budget-friendly option. Contact us today to get a free 3D printing design quote so we can help you move your business forward with additive manufacturing.

The post Additive Manufacturing and 3D Printing in 2019 appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.