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Taguchi-Based Experimental Investigation and Modeling of 3D-Printed PEEK Parts as Biomedical Implants using Fused Deposition Modeling for Improving Mechanical Strength and Surface Quality

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Abstract

Three-dimensional (3D) printing is a form of additive manufacturing that employs digital model data to build real objects by layering on materials. The technology has found use in the automotive, aerospace, and biomedical industries. Fused deposition modeling (FDM) is a popular 3D printing technique used for production of thermoplastic polymer materials. In this work, polyether ether ketone (PEEK) material being used a biomaterial for a biomedical implant is investigated to evaluate improvement of mechanical strength and surface quality of the print. Infill density (ID), infill pattern (IP), and printing speed (PS) are considered as process parameters to study their influence on responses, viz., surface roughness (SR), ultimate tensile strength (UTS), and Rockwell hardness (RH). The developed predictive models for three responses are found accurate with higher values of R2 and R2 (adj) and maximum average error found as 1.38% for hardness. The infill pattern, followed by layer height, has the greatest impact on the performance measures. Increased infill density and low printing speed produce strong part having maximum ultimate tensile strength. According to a SEM image, the best material pack to generate strong specimens with the highest mechanical strength is one that has the highest infill density and the slowest printing speed (UTS = 59.09 MPa; RH = 64.31). Parametric optimization to optimize single and multi-responses was carried out using desirability analysis (DA) and the results show that 72.93% infill density, printing speed of 25 mm/sec, and gyroid pattern having composite desirability value of 0.8884 are found optimum.

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Authors and Affiliations

  1. Department of Mechanical Engineering, North Eastern Regional Institute of Science and Technology, Nirjuli, Arunachal Pradesh, 791109, India

    Jyotisman Borah & M. Chandrasekaran

  2. Department of Mechanical Engineering, Mahendra Institute of Technology (Autonomous), Mallasamudram, Namakkal District, 637503, Tamil Nadu, India

    L. Selvarajan

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  1. Jyotisman Borah
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Borah, J., Chandrasekaran, M. & Selvarajan, L. Taguchi-Based Experimental Investigation and Modeling of 3D-Printed PEEK Parts as Biomedical Implants using Fused Deposition Modeling for Improving Mechanical Strength and Surface Quality. J. of Materi Eng and Perform (2023). https://doi.org/10.1007/s11665-023-09036-4

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