Material Characterization of High-Performance Polymers for Additive Manufacturing (AM) in Aerospace Mechanical Design

Additive manufacturing has profoundly influenced the aerospace industry since its inception, offering unmatched design freedom, cost reduction, rapid prototyping, and enhanced supply-chain efficiency. High-performance polymers like ULTEM (TM) and PEEK have emerged, known for their strength, temperature resistance, chemical resistance, and lightweight properties. However, the mechanical properties of materials produced through additive manufacturing can vary due to several factors in the printing process, leading to some degree of uncertainty. To address this, the mechanical properties of ULTEM (TM) 9085 and ULTEM (TM) 1010 were characterized through mechanical tests. These tests aimed to provide valuable insights into the performance of these materials to be able to run more practical and precise analyses in concurrent design facilities for topological optimization. The results were also compared to materials used in traditional manufacturing methods for components such as flexures and compliant mechanisms. While not fully able to replace metals in high-stress environments, they can be effectively utilized in specific applications. The tests performed contribute to the building of databases that would allow for faster access to critical data that could be applied to a simulation to predict structural performance. This research highlights the potential of additive manufacturing to revolutionize material use in the aerospace sector.