Ultra- and high-performance polymers for material extrusion additive manufacturing: Recent advancements, challenges, and optimization perspectives

IF 31.6 1区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials Science and Engineering: R: Reports Pub Date : 2025-08-21 DOI:10.1016/j.mser.2025.101086

Nectarios Vidakis , Markos Petousis , Maria Spyridaki , Nikolaos Mountakis , Evgenia Dimitriou , Nikolaos Michailidis

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Abstract

Material extrusion-based additive manufacturing (MEXAM) has emerged as a transformative technology for ultra-performance polymers (UPPs) and high-performance polymers (HPPs), enabling their use in demanding applications across diverse industries such as aerospace, automotive, medical, and defense. Their high strength-to-weight ratio, heat resistance, chemical stability, and performance retention under harsh conditions perfectly match the high potential of additive manufacturing for cost-effectiveness, flexibility, and adaptability. Among the most studied UPPs/HPPs, Polyimide (PΙ), polyetherketoneketone (PEKK), and polyetheretherketone (PEEK) have gained substantial attention due to their printability and superior functional properties. Despite these advantages, MEXAM of UPPs and HPPs presents considerable challenges. This review provides a comprehensive analysis of the molecular, rheological, thermal, and structural characteristics of UPPs/HPPs and their major composites that influence their printability and performance. A comparative evaluation of their advantages and limitations is presented, along with a discussion on recent advancements in process optimization. Research efforts for the optimization of MEXAM process control parameters were reviewed and interpreted. Furthermore, this work explores the integration of Artificial Intelligence (AI)-assisted optimization strategies to enhance processing efficiency and material properties. This study identifies key research gaps and highlights opportunities for future advancements in the field of MEXAM for UPPs and HPPs.

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用于材料挤压增材制造的超高性能聚合物：最新进展、挑战和优化观点

基于材料挤压的增材制造（MEXAM）已经成为超高性能聚合物（UPPs）和高性能聚合物（HPPs）的变革性技术，使其能够在航空航天、汽车、医疗和国防等不同行业的苛刻应用中使用。它们的高强度重量比、耐热性、化学稳定性和恶劣条件下的性能保持完全符合增材制造在成本效益、灵活性和适应性方面的高潜力。在研究最多的UPPs/HPPs中，聚酰亚胺（PΙ）、聚醚酮酮（PEKK）和聚醚醚酮（PEEK）由于其可印刷性和优越的功能特性而获得了大量关注。尽管有这些优势，UPPs和HPPs的MEXAM仍然面临着相当大的挑战。本文综述了UPPs/HPPs及其主要复合材料的分子、流变、热学和结构特性，并对影响其可打印性和性能进行了全面分析。对它们的优点和局限性进行了比较评价，并讨论了工艺优化的最新进展。综述了国内外在MEXAM工艺控制参数优化方面的研究成果。此外，本工作探讨了人工智能（AI）辅助优化策略的集成，以提高加工效率和材料性能。这项研究确定了关键的研究差距，并强调了未来在upp和hpp的MEXAM领域取得进展的机会。

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来源期刊

Materials Science and Engineering: R: Reports 工程技术-材料科学：综合

CiteScore

60.50

自引率

0.30%

发文量

审稿时长

34 days

期刊介绍： Materials Science & Engineering R: Reports is a journal that covers a wide range of topics in the field of materials science and engineering. It publishes both experimental and theoretical research papers, providing background information and critical assessments on various topics. The journal aims to publish high-quality and novel research papers and reviews. The subject areas covered by the journal include Materials Science (General), Electronic Materials, Optical Materials, and Magnetic Materials. In addition to regular issues, the journal also publishes special issues on key themes in the field of materials science, including Energy Materials, Materials for Health, Materials Discovery, Innovation for High Value Manufacturing, and Sustainable Materials development.