Additive manufacturing (AM), particularly through techniques such as Fused Filament Fabrication (FFF), presents revolutionary opportunities in various industries, including aerospace, by allowing for the production of complex geometrical parts without the need for extensive tooling. However, one significant hurdle that persists is achieving strong and reliable bonding between high-performance polymers like PEEK (poly ether ether ketone) and carbon fiber-reinforced composites. The integrity and mechanical strength of 3D-printed parts are fundamentally dependent on the quality of bonding between the polymer filaments. This bonding is predominantly influenced by the thermal energy during the printing process, where the polymer is extruded in a semi-molten state and must fuse properly with its preceding layers. In the case of high-performance materials like PEEK and PEI (polyetherimide), this is particularly challenging due to their high processing temperatures which introduce high thermal gradients. Read more: addcomposites.com/...