Extrudability, printability, and strain rate sensitivity metrics of lightweight thermoplastic polyimide (PI) in material extrusion (MEX) additive manufacturing

Abstract

Among the high-performance polymers (HPPs) deployed in material extrusion 3D printing, thermoplastic polyimide (PI or TPI) dominates in terms of chemical stability and thermomechanical performance. Such features, suitable for challenging operational environments, nationalize and defend the remarkably expensive filament market. This study comprehensively explores the physical, thermal, rheological, key mechanical, and strain rate sensitivity metrics of PI. The PI pellets were melt-extruded into filaments under optimized thermomechanical control settings. A detailed experimental course, including elemental and chemical characterization, scanning electron microscopy morphological assessments, and Raman spectroscopy, was implemented. Thermal stability and phase transitions were determined using differential scanning calorimetry and thermogravimetric analysis. The rheological response was determined through viscosity/stress tests and melt flow rate measurements at various temperatures. A dynamic mechanical analysis was performed. Moreover, standard quasi-static mechanical tests documented the tensile, bending, impact, and microhardness performance of 3D printed specimens. Finally, the strain rate sensitivity metrics of the PI were derived from forty-five 3D printed tensile specimens subjected to nine steps with elongation speeds ranging from 10 to 300 mm min⁻¹. Remarkably, the sample tested at 25 mm min⁻¹ exhibited optimal mechanical performance, whereas a superior toughness was observed at 300 mm min⁻¹. The strain rate sensitivity index and various other rate-dependent interactions were determined and comprehensively discussed. The inclusive findings herein provide critical insights into the overall performance of thermoplastic polyimide in additive manufacturing, aiming to support its broader exploitation in advanced engineering applications.