Polyetheretherketone (PEEK), as fabricated by material extrusion, has the unique advantages of strength-to-mass ratio and biocompatibility in medical applications, yet its practical application is severely hindered by the insufficient interlayer adhesion, typically in the ranges of 5–20 MPa, far below the strength requirement of bone replacement of ∼100 MPa. In this study, we present a novel powder-based hot isostatic pressing (PHIP) treatment to enhance the tensile strength of PEEK manufactured through the material extrusion method. By combining it with material extrusion printing parameters optimization, we successfully achieved a remarkable improvement in interlayer adhesion and tensile strength. Specifically, the tensile strength in the Z-XY was measured to be 102.6 ± 0.7 MPa, 423.5 % higher than that of the state-of-the-art PEEK extrusion specimens (19.6 ± 6.1 MPa), 3.5 % higher than the optimized X-YZ specimen reported in the literature (98.9 ± 2.3 MPa), and comparable to the tensile strength of injection molded PEEK with a value of 107.7 ± 0.7 MPa. The improvement in mechanical properties was attributed to the improved molecular diffusion and crystallinity of PEEK, as observed through scanning electron microscope (SEM) and differential scanning calorimetry (DSC) analysis. Microcomputer tomography (micro-CT) results confirmed the extensive and deep fusion between the extruded filaments and the elimination of most voids. Additionally, the PHIP method demonstrated superior shape retention stability compared to regular thermal annealing. These findings demonstrate the viability of significantly improving the mechanical properties of material extrusion PEEK via PHIP towards its bulk limit and offer a promising solution for enhancing the practical applications of PEEK manufactured through material extrusion.

聚醚醚酮（PEEK）通过材料挤出制备，在医疗应用中具有独特的强度质量比和生物相容性优势，但层间粘合力不足（通常在5-20 MPa范围内）严重阻碍了其实际应用，远低于~100 MPa的骨置换强度要求。在这项研究中，我们提出了一种新型粉末基热等静压 (PHIP) 处理方法，以提高通过材料挤出方法制造的 PEEK 的拉伸强度。通过将其与材料挤出打印参数优化相结合，我们成功实现了层间附着力和拉伸强度的显着提高。具体而言，测得Z-XY方向的拉伸强度为102.6±0.7MPa，423。比最先进的 PEEK 挤出样品 (19.6 ± 6.1 MPa) 高 5%，比文献报道的优化 X-YZ 样品 (98.9 ± 2.3 MPa) 高 3.5%，并且与拉伸强度相当注塑 PEEK 的强度值为 107.7 ± 0.7 MPa。通过扫描电子显微镜 (SEM) 和差示扫描量热法 (DSC) 分析观察到，机械性能的改善归因于 PEEK 分子扩散和结晶度的改善。微计算机断层扫描（micro-CT）结果证实了挤出细丝之间存在广泛而深度的融合，并且消除了大部分空隙。此外，与常规热退火相比，PHIP 方法表现出优异的形状保持稳定性。