{"id":{"repo_id":"exeter","oai_identifier":"oai:figshare.com:article/32113372"},"canonical_url":"https://search.dev.ndltd.org/etd/exeter/oai:figshare.com:article/32113372","repository":{"repo_id":"exeter","name":"University of Exeter","base_url":"https://api.figshare.com/v2/oai"},"display":{"title":"On the development of new PolyArylEtherKetone bulk solids for Powder Bed Fusion","abstract":"Powder Bed Fusion (PBF) of polymers, a form of Additive Manufacturing (AM) is an established manufacturing process where fine powdered materials are consolidated by an energy source to form polymeric parts without the need for moulds or tooling. A requirement of the process is a fine powder feedstock material of suitable particle size with flow and spreading characteristics that allow thin layers of material to be spread at high temperatures during processing. PolyArylEtherKetones (PAEK’s) are a family of high performance thermoplastic polymers that can be processed with specific high temperature PBF systems. Although commercial interest in the use of high performance polymers for PBF is growing, the manufacture of suitable feedstock powder materials remains challenging due to their resistance to typical processing methods. In this research study, fourteen PAEK grades supplied by Victrex Manufacturing Ltd, including Victrex™ PEEK 450PF, Victrex™ PEK HT22PF and developmental LMPAEK™ were received in fine powdered form. Ten of the grades were split and thermally pre-processed to improve flow and bulk density, creating a total group of twenty-four powder bulk solid candidates for study. Each of the PAEK samples was analysed for Particle Size Distribution (PSD) and morphology, and then the bulk and dynamic properties were measured using a dry powder rheometer. The statistical relationships between size, shape, bulk and dynamic flow properties were evaluated and quantified. The PAEK samples were tested using the specific spreading process used in high temperature PBF and visually assessed. A bespoke apparatus was designed and constructed to replicate the spreading process whilst digital images of the powder surface were captured. Image processing was used to quantify the smoothness of the powder surfaces, and the statistical relationships between the size, shape, bulk and dynamic properties and the spreading quality were evaluated. Once a full understanding of the PAEK samples was established, eight of the twenty-four candidate samples were chosen for parts fabrication with the PBF process, based on the fundamental understanding of the bulk and dynamic flow properties. Mechanical test specimens and packed powder bed samples were created via the PBF process, and the links between the feedstock material’s fundamental form (size and shape) and the Ultimate Tensile Strength (UTS) of the manufactured components established. Finally the low shear rate melt viscosity of some of the final PAEK samples was tested to fully understand its influence on the milling process output, and its subsequent influence on the output of the PBF process.<p></p>","abstract_html":"Powder Bed Fusion (PBF) of polymers, a form of Additive Manufacturing (AM) is an established manufacturing process where fine powdered materials are consolidated by an energy source to form polymeric parts without the need for moulds or tooling. A requirement of the process is a fine powder feedstock material of suitable particle size with flow and spreading characteristics that allow thin layers of material to be spread at high temperatures during processing. PolyArylEtherKetones (PAEK’s) are a family of high performance thermoplastic polymers that can be processed with specific high temperature PBF systems. Although commercial interest in the use of high performance polymers for PBF is growing, the manufacture of suitable feedstock powder materials remains challenging due to their resistance to typical processing methods. In this research study, fourteen PAEK grades supplied by Victrex Manufacturing Ltd, including Victrex™ PEEK 450PF, Victrex™ PEK HT22PF and developmental LMPAEK™ were received in fine powdered form. Ten of the grades were split and thermally pre-processed to improve flow and bulk density, creating a total group of twenty-four powder bulk solid candidates for study. Each of the PAEK samples was analysed for Particle Size Distribution (PSD) and morphology, and then the bulk and dynamic properties were measured using a dry powder rheometer. The statistical relationships between size, shape, bulk and dynamic flow properties were evaluated and quantified. The PAEK samples were tested using the specific spreading process used in high temperature PBF and visually assessed. A bespoke apparatus was designed and constructed to replicate the spreading process whilst digital images of the powder surface were captured. Image processing was used to quantify the smoothness of the powder surfaces, and the statistical relationships between the size, shape, bulk and dynamic properties and the spreading quality were evaluated. Once a full understanding of the PAEK samples was established, eight of the twenty-four candidate samples were chosen for parts fabrication with the PBF process, based on the fundamental understanding of the bulk and dynamic flow properties. Mechanical test specimens and packed powder bed samples were created via the PBF process, and the links between the feedstock material’s fundamental form (size and shape) and the Ultimate Tensile Strength (UTS) of the manufactured components established. Finally the low shear rate melt viscosity of some of the final PAEK samples was tested to fully understand its influence on the milling process output, and its subsequent influence on the output of the PBF process.&lt;p&gt;&lt;/p&gt;","abstract_has_math":false,"creators":["Richard Davies (21068291)"],"institution":null,"degree_name":null,"degree_level":null,"degree_discipline":null,"degree_department":null,"school":null,"contributors":[],"advisors":[],"committee_chairs":[],"committee_members":[],"year":2026,"date_issued":"2026-04-27T00:00:00Z","date_published":"2026-04-27T00:00:00Z","updated_at":"2026-07-27T19:33:18Z","subjects":["PolyArylEtherKetone","Powder Bed Fusion","Laser Sintering","3D Printing","Polymers","Bulk Solids","Fine Powder","Powder Rheometry","Particle Size Distribution","Additive Manufacturing"],"languages":[],"rights":["All rights reserved"],"rights_urls":[],"identifier_entries":[{"key":"dc:identifier","label":"Identifier","values":["10779/exe.32113372.v1"],"render_values":[{"text":"10779/exe.32113372.v1","href":null,"code":true}]}]},"links":{"outbound_url":null,"outbound_label":null,"outbound_source":null},"metadata_groups":[{"id":"people","label":"People","entries":[{"key":"dc:creator","label":"Author","values":["Richard Davies (21068291)"]}]},{"id":"academic_context","label":"Academic Context","entries":[{"key":"dc:date","label":"Dc Date","values":["2026-04-27T00:00:00Z"]},{"key":"dc:relation","label":"Dc Relation","values":["https://figshare.com/articles/thesis/On_the_development_of_new_PolyArylEtherKetone_bulk_solids_for_Powder_Bed_Fusion/32113372"]},{"key":"dc:type","label":"Dc Type","values":["Text","Thesis"]}]},{"id":"subjects_keywords","label":"Subjects and Keywords","entries":[{"key":"dc:subject","label":"Dc Subject","values":["PolyArylEtherKetone","Powder Bed Fusion","Laser Sintering","3D Printing","Polymers","Bulk Solids","Fine Powder","Powder Rheometry","Particle Size Distribution","Additive Manufacturing"]}]},{"id":"language_rights","label":"Language and Rights","entries":[{"key":"dc:rights","label":"Dc Rights","values":["All rights reserved"]}]},{"id":"identifiers","label":"Identifiers","entries":[{"key":"dc:identifier","label":"Identifier","values":["10779/exe.32113372.v1"]}]},{"id":"additional","label":"Additional Metadata","entries":[{"key":"dc:description","label":"Description","values":["Powder Bed Fusion (PBF) of polymers, a form of Additive Manufacturing (AM) is an established manufacturing process where fine powdered materials are consolidated by an energy source to form polymeric parts without the need for moulds or tooling. A requirement of the process is a fine powder feedstock material of suitable particle size with flow and spreading characteristics that allow thin layers of material to be spread at high temperatures during processing. PolyArylEtherKetones (PAEK’s) are a family of high performance thermoplastic polymers that can be processed with specific high temperature PBF systems. Although commercial interest in the use of high performance polymers for PBF is growing, the manufacture of suitable feedstock powder materials remains challenging due to their resistance to typical processing methods. In this research study, fourteen PAEK grades supplied by Victrex Manufacturing Ltd, including Victrex™ PEEK 450PF, Victrex™ PEK HT22PF and developmental LMPAEK™ were received in fine powdered form. Ten of the grades were split and thermally pre-processed to improve flow and bulk density, creating a total group of twenty-four powder bulk solid candidates for study. Each of the PAEK samples was analysed for Particle Size Distribution (PSD) and morphology, and then the bulk and dynamic properties were measured using a dry powder rheometer. The statistical relationships between size, shape, bulk and dynamic flow properties were evaluated and quantified. The PAEK samples were tested using the specific spreading process used in high temperature PBF and visually assessed. A bespoke apparatus was designed and constructed to replicate the spreading process whilst digital images of the powder surface were captured. Image processing was used to quantify the smoothness of the powder surfaces, and the statistical relationships between the size, shape, bulk and dynamic properties and the spreading quality were evaluated. Once a full understanding of the PAEK samples was established, eight of the twenty-four candidate samples were chosen for parts fabrication with the PBF process, based on the fundamental understanding of the bulk and dynamic flow properties. Mechanical test specimens and packed powder bed samples were created via the PBF process, and the links between the feedstock material’s fundamental form (size and shape) and the Ultimate Tensile Strength (UTS) of the manufactured components established. Finally the low shear rate melt viscosity of some of the final PAEK samples was tested to fully understand its influence on the milling process output, and its subsequent influence on the output of the PBF process.<p></p>"]},{"key":"dc:title","label":"Title","values":["On the development of new PolyArylEtherKetone bulk solids for Powder Bed Fusion"]}]}],"canonical_facts":{"dc:creator":["Richard Davies (21068291)"],"dc:date":["2026-04-27T00:00:00Z"],"dc:description":["Powder Bed Fusion (PBF) of polymers, a form of Additive Manufacturing (AM) is an established manufacturing process where fine powdered materials are consolidated by an energy source to form polymeric parts without the need for moulds or tooling. A requirement of the process is a fine powder feedstock material of suitable particle size with flow and spreading characteristics that allow thin layers of material to be spread at high temperatures during processing. PolyArylEtherKetones (PAEK’s) are a family of high performance thermoplastic polymers that can be processed with specific high temperature PBF systems. Although commercial interest in the use of high performance polymers for PBF is growing, the manufacture of suitable feedstock powder materials remains challenging due to their resistance to typical processing methods. In this research study, fourteen PAEK grades supplied by Victrex Manufacturing Ltd, including Victrex™ PEEK 450PF, Victrex™ PEK HT22PF and developmental LMPAEK™ were received in fine powdered form. Ten of the grades were split and thermally pre-processed to improve flow and bulk density, creating a total group of twenty-four powder bulk solid candidates for study. Each of the PAEK samples was analysed for Particle Size Distribution (PSD) and morphology, and then the bulk and dynamic properties were measured using a dry powder rheometer. The statistical relationships between size, shape, bulk and dynamic flow properties were evaluated and quantified. The PAEK samples were tested using the specific spreading process used in high temperature PBF and visually assessed. A bespoke apparatus was designed and constructed to replicate the spreading process whilst digital images of the powder surface were captured. Image processing was used to quantify the smoothness of the powder surfaces, and the statistical relationships between the size, shape, bulk and dynamic properties and the spreading quality were evaluated. Once a full understanding of the PAEK samples was established, eight of the twenty-four candidate samples were chosen for parts fabrication with the PBF process, based on the fundamental understanding of the bulk and dynamic flow properties. Mechanical test specimens and packed powder bed samples were created via the PBF process, and the links between the feedstock material’s fundamental form (size and shape) and the Ultimate Tensile Strength (UTS) of the manufactured components established. Finally the low shear rate melt viscosity of some of the final PAEK samples was tested to fully understand its influence on the milling process output, and its subsequent influence on the output of the PBF process.<p></p>"],"dc:identifier":["10779/exe.32113372.v1"],"dc:relation":["https://figshare.com/articles/thesis/On_the_development_of_new_PolyArylEtherKetone_bulk_solids_for_Powder_Bed_Fusion/32113372"],"dc:rights":["All rights reserved"],"dc:subject":["PolyArylEtherKetone","Powder Bed Fusion","Laser Sintering","3D Printing","Polymers","Bulk Solids","Fine Powder","Powder Rheometry","Particle Size Distribution","Additive Manufacturing"],"dc:title":["On the development of new PolyArylEtherKetone bulk solids for Powder Bed Fusion"],"dc:type":["Text","Thesis"]},"updated_at":"2026-07-27T19:33:18Z"}