Optimization of process parameters for fused filament fabrication of ULTEM 1010

Fused Filament Fabrication is an Additive Manufacturing process increasingly used to manufacture advanced products from engineering polymers. ULTEM 1010 is particularly well-suited for this purpose due to its exceptional physical and chemical properties, which support high-performance applications across the aerospace, medical, automotive, food, and mechanical industries. However, its adoption remains limited and less common than that of other polyetherimides due to insufficient knowledge of the process. In this study, the effects of extrusion temperature, nozzle speed and layer thickness on the surface and material properties of products were systematically investigated through Scanning Electron Microscopy, X-ray microtomography, tensile tests, indentation tests, and Fourier Transform Infrared Spectroscopy. Synchrotron radiation was employed to further characterize the structure of selected samples at an unexplored scale, while Ultra-High Vacuum testing was conducted to validate the process for special applications across aerospace engineering, nuclear fusion, laser technology, electronics, and high-energy physics. The results provide new insights to optimize the process for advanced engineering applications.