Surface Roughness of Polyetheretherketone Printed by Fused Deposition Modeling: A Pilot Study Investigating the Impact of Print Layer Thickness and Polishing Method

Polyetheretherketone is a high-performance thermoplastic polymer that can be used in 3D printing by fused deposition modeling, and is a promising material for dental applications. Some printing parameters are sensitive and can influence the properties of the printed object. Thus, this work aims to evaluate the influence of the print layer thickness on the surface roughness of polyetheretherketone before and after polishing and to verify the effectiveness of the polishing method used, as well as to compare it with the results obtained using polymethyl methacrylate as the control group. Specimens with different impression layer thicknesses were printed with polyetheretherketone (Group A—0.1 mm and Group B—0.3 mm). Additionally, a control group with polymethyl methacrylate specimens was milled. Roughness evaluation was conducted using a contact profilometer after the specimens had been printed (before polishing). Then, silicon carbide sandpaper was used to polish the surface, and the roughness was reassessed. Differences were observed between specimens regarding the print layer thickness and the roughness, with the 0.3 mm layer thickness showing the lowest roughness values. The results of this pilot study suggest that the surface roughness of fused deposition modeling printed polyetheretherketone is influenced by print layer thickness, with the lowest roughness seen at a thickness of 0.3 mm.