Enabling consumer-grade 3D printing of high-performance thermoplastics: A systematic investigation of low-temperature PAEK processing and mechanical properties

High-performance polyaryletherketone (PAEK) faces critical processing challenges in additive manufacturing, including elevated melting temperatures (343 °C), high melt viscosity, and crystallization-induced defects. This study investigates a low-temperature polyaryletherketone (LT-PAEK) engineered for consumer-grade fused filament fabrication (FFF). Systematic comparison of low-speed (60 mm/s) and high-speed (250 mm/s) printing revealed that LT-PAEK's reduced melting point (306.5 °C) and low crystallinity (<20%) enable stable processing while suppressing warping. High-speed printed specimens achieved superior mechanical performance, with horizontal tensile strength reaching 111.02 MPa post-annealing. Micro-CT analysis confirmed exceptionally low porosity (1.18%), attributed to enhanced melt flow during rapid deposition. Fracture surface examination revealed transition from interlayer delamination to transgranular failure after annealing, confirming improved interfacial bonding. High-speed printing reduced processing time by 13.1–35.9% while maintaining geometric accuracy for complex architectures. This work establishes LT-PAEK as a cost-effective alternative to conventional PAEK for demanding applications in aerospace and biomedical sectors.