Enhanced mechanical properties of continuous carbon fiber-reinforced PEEK composites via process parameters optimization and assisted infrared irradiation heating

The 3D-printed continuous carbon fiber-reinforced composites (CCFRCs) have emerged as a promising approach for fabricating high-performance composites due to their high degree of automation, design flexibility, and cost-effectiveness. Polyether-ether-ketone (PEEK) is widely recognized as an ideal thermoplastic matrix material for CCFRCs because of its outstanding mechanical properties, thermal resistance, and chemical stability. Nevertheless, the fabrication of continuous carbon fiber-reinforced PEEK (CCF/PEEK) composites via 3D printing is still confronted with significant processing obstacles. The high viscosity and elevated melting temperature of the composites lead to weak interlayer bonding and high porosity, which severely undermine the overall performance and quality of the printed composites. To address these issues, this study adopted an orthogonal experimental design to explore the synergistic effects of process parameters, including printing temperature, printing speed, and platform temperature, and systematically optimize critical variables. Furthermore, a delicate infrared irradiation (IR) heater was designed and incorporated to improve interlayer bonding and reduce porosity. The results demonstrate that the combination of optimized process parameters and assisted IR heating enables stable and high-quality 3D-printed CCF/PEEK composites.