Fused filament fabrication (FFF) has emerged as a versatile additive manufacturing (AM) process for high-performance polymers, combining accessibility with the capability to process advanced materials such as polyether ether ketone (PEEK). This thesis focuses on process optimization of multi-material FFF using carbon fiber-reinforced PEEK (CF-PEEK) and laser direct structurable PEEK (LDS-PEEK) for CubeSat applications. CF-PEEK offers excellent stiffness and thermal resistance, while LDS-PEEK enables electronic integration; however, their simultaneous processing poses challenges due to differences in thermal expansion and solidification behavior.
A two-phase experimental methodology was applied: baseline CF-PEEK panels were optimized through parameter screening, followed by dual-material CF-PEEK/LDS-PEEK printing to assess interfacial compatibility. Statistical design methods including ANOVA and response surface modelling were employed to identify the most significant factors. Results indicated that infill orientation and thermal conditions dominated warp behavior in CF-PEEK, while raster angle and layer height strongly influenced dual-material dimensional stability. Microscopic inspection confirmed continuous bonding and localized interlocking between the two materials. This study establishes an experimental framework for the feasibility of multi-material CF-PEEK/LDS-PEEK printing, highlighting a promising pathway for multifunctional CubeSat panel fabrication and broader aerospace applications. .
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