Impact of Layer Thickness on Mechanical Properties and Surface Roughness of FDM-Printed Carbon Fiber-PEEK Composite

Fused deposition modeling (FDM)-based three-dimensional (3D) fabrication offers a viable approach to manufacturing highly customized carbon fiber-reinforced polyether ether ketone (CFR-PEEK) components with complex geometries. However, the mechanical properties and surface roughness of FDM-fabricated parts are strongly influenced by processing parameters, particularly layer thickness. This study investigates the influence of layer thickness (0.1 mm and 0.2 mm) on the surface roughness, crystallinity, mechanical properties, and morphological characteristics of FDM-printed 10% CFR-PEEK specimens. The specimens were characterized using mechanical testing, differential scanning calorimetry (DSC), confocal laser microscopy, X-ray micro-computed tomography (µCT), and scanning electron microscopy (SEM). The results show that specimens printed with a 0.2 mm layer thickness exhibit higher crystallinity and ball indentation hardness while also showing increased surface roughness and porosity, with µCT analysis revealing larger and more spatially clustered voids near the sub-perimeter regions. In contrast, specimens printed with a 0.1 mm layer thickness demonstrate higher tensile strength, elastic modulus, elongation at break, and compressive stress. SEM fractography further indicates improved interlayer bonding and a relatively cohesive fracture surface in specimens printed with a 0.1 mm layer thickness. These findings demonstrate clear layer-thickness-dependent processing–structure–property relationships in FDM-printed CFR-PEEK composites and provide guidance for optimizing printing parameters to achieve improved mechanical performance.