Additive manufacturing is poised to redefine how critical components are designed and produced, yet most printers remain unable to process super-polymers such as polyether ether ketone (PEEK). Our senior project removes that barrier by converting a legacy Stratasys SST1200 ES into a fully open-source, high-temperature platform. The retrofit combines liquid-cooled extrusion, a 145 °C MIC6 build surface, closed-loop chamber heating, and Klipper-based control to deliver stable 400 °C nozzle performance which is essential for PEEK’s exceptional mechanical, thermal, and chemical properties. Rigorous validation shows repeatable dimensional accuracy and strong inter-layer bonding across PEEK, PPS, and carbon-fiber composites, all achieved for less than USD 2 000 in materials. By democratizing access to super-polymer printing, the project unlocks affordable rapid prototyping and end-use production for aerospace, medical, and semiconductor applications, offering capabilities once reserved for far more expensive industrial systems.
Subjects: Mechanical Engineering
