Powder casting of polyetheretherketone and polyphenylene sulfone: Sintering

Systematic studies of the influence of the basic powder characteristics and its sintering conditions on the physical and mechanical properties of samples intended for the implementation of the technology of powder injection molding of products from typical heat-resistant high performance engineering polymers - crystallizing polyetheretherketone (PEEK) and amorphous polyphenylene sulfone (PPSu) - were carried out. Polymers with different MW were synthesized as initial materials and powders with different sizes and bulk density were obtained. The influence of these parameters on the nature of powder sinterability and, as a consequence, on their elastic modulus and tensile strength was shown. Optimum characteristics for bulk density and sintering temperature were established, which provide maximum values of mechanical characteristics of the molded samples. The results of the fundamental research conducted allowed us to produce two typical products for biomedicine - an intervertebral cage (an implant replacing a removed vertebra) and a blood dialyzer part. [Display omitted] •Products made from high-temperature engineering poplymers can be produced using powder casting.•The quality of the products depends on the properties of the powder and the sintering conditions.•The best sintering temperature depends on the MW and the fractional composition of the powder.•The correct mode of sintering allows us to obtain products corresponding by quality to cast samples.•The addition of nanosized aerosil particles improves the technological properties of the powder.