A deep dive into the power of high-temp 3D printing in aerospace manufacturing with PEEK.
High-Temp Parts in Space? Yes, Literally.
What started as a mysterious call from Advanced Fuel Research (AFR)—a NASA contractor—evolved into one of the most technically demanding and rewarding projects in Vision Miner’s early history. The mission? Produce ultra-small, high-temp components for a fuel filtration system used in the spacewalk suits.
The Challenge: Carbon Fiber PEEK Micro Parts
AFR needed parts made from carbon fiber PEEK, one of the toughest materials to print in additive manufacturing. Not only were the components tiny—some just a few millimeters thick—but they also required precise internal geometries to function as part of a filtration system for gases like ammonia and formaldehyde in space.
The catch? No one else could do it. Multiple manufacturers were contacted, but only one team could figure out how to slice, print, and post-process the parts effectively: Vision Miner.
Iterating Through Complexity
The first parts attempted were riddled with fine cross-hatching and microscopic channels. Vision Miner had to get creative with slicing strategies to convince the software to produce layers under 0.25mm—a task that led to constant nozzle clogs and frequent part failures.
Custom toolpaths were generated to build cross-hatched layers that wouldn’t overlap during the extrusion phase, ensuring uniform thickness and maintaining open internal channels. These parts weren’t even the final products—they were substrates to be compressed and thermally bonded into the final filtration modules.
Slicer Settings That Made It Work
The devil was in the details. Settings like:
- Extrusion width: 0.2mm
- Minimum extrusion length: 2mm
- Layer height: 0.2mm (with carbon fiber material)
- Temperature: Up to 415°C
- Cooling: 15%
…were carefully tuned to maintain printability without compromising geometry or mechanical integrity. Even then, nozzles lasted for just a handful of prints before they needed replacing.
Post-Processing and Carbonization
After printing, the parts underwent a heat compression process to form a single, larger filtration component. This was followed by high-temp carbonization, with samples tested in tube furnaces at up to 800°C using nitrogen as a carrier gas. Remarkably, PEEK retained its shape even at these extreme temps—a testament to its suitability for aerospace applications.
The End Use: Keeping Spacewalkers Safe
These tiny parts played a vital role in filtering hazardous gases in a new generation of NASA spacewalk suits. While they weren’t the final part themselves, they were essential raw components, designed with such precision that they enabled successful layered integration into a functioning filtration system.
Lessons Learned (and Why It Matters)
This project taught more than just technical skills—it reinforced a culture of relentless iteration, problem solving, and engineering creativity. High-temp printing remains a specialized craft, and Vision Miner continues to lead the charge with real-world experience in aerospace-grade additive manufacturing.
Need Help With Your High-Temp Project?
Whether you’re working on a defense prototype, aerospace component, or next-gen robotics part, Vision Miner is your one-stop shop for high-temp 3D printing, carbon fiber composites, SLA, SLS, and 3D scanning.
We’re not just here to sell you machines—we’re here to solve problems. If you’re unsure about materials, overthinking your setup, or just want honest advice, reach out. Chances are we can save you time, money, and a whole lot of frustration.
Visit VisionMiner.com or shoot us a message. Let’s print something impossible together.