Research on the Optimization of Z‐Direction Forming Process for Additively Manufactured Polyetheretherketone Composite in Environments Without Bed and Chamber Heating

ABSTRACT Fused Filament Fabrication (FFF) is widely used in manufacturing, but high‐performance prints typically require a heated bed and high‐temperature chamber due to process limitations. Therefore, it is essential to investigate forming processes under low‐temperature conditions. This study investigates the optimization of process parameters for fabricating short carbon fiber‐reinforced polyetheretherketone (SCF/PEEK) composites via FFF without bed and chamber heating. A three‐factor, three‐level experimental design was employed to evaluate the effects of nozzle temperature, printing speed, and layer thickness on the Z‐direction flexural performance. Analysis of variance (ANOVA) was conducted to determine the statistical significance of each factor. In addition, thermal and morphological characterizations were carried out to elucidate the relationship between processing conditions and material microstructure. The results reveal that layer thickness has a statistically significant effect on flexural strength, while nozzle temperature and printing speed show no significant influence. The optimal combination of process parameters was 440°C nozzle temperature, 50 mm/s printing speed, and 0.2 mm layer thickness, which led to a maximum flexural strength of 50.85 MPa, representing a 10.2% improvement compared to the maximum experimental results. The present work may provide guidance for the additive manufacturing of large composite components in low‐temperature in‐orbit environments.