Polyaryletherketone (paek) Gels and Aerogels

THE CHALLENGE

Developing lightweight high-performance aerogels from advanced polymers like PEEK and PEKK presents a major business and manufacturing challenge due to the complex and costly processing these materials require. Their exceptional thermal and chemical stability make them ideal for demanding applications in aerospace energy and environmental sectors but their poor solubility and high melt viscosity make traditional fabrication methods inefficient and difficult to scale. Current techniques rely on toxic solvents, high temperatures, and energy-intensive steps like supercritical drying which increase production costs and environmental impact. These processes also produce fragile structures with inconsistent pore sizes making them unsuitable for precise applications or 3D printing. The lack of scalable environmentally friendly and cost-effective manufacturing methods for shaping these polymers into porous structures limits their commercial potential despite their superior material properties.

OUR SOLUTION

We offer a scalable and environmentally friendly method to produce high-performance aerogels from PAEK polymers like PEEK and PEKK using a unique thermoreversible gelation process. By dissolving the polymer in a safe high-boiling solvent and inducing gelation through controlled cooling, we avoid the need for harsh chemicals or complex crosslinking steps. This method not only reduces energy consumption and processing time but also enables the creation of lightweight porous materials with strong mechanical properties and customizable 3D shapes through additive manufacturing. With tunable porosity, high surface area, and improved structural integrity this technology opens new business opportunities in sectors such as aerospace clean energy and high-end filtration where lightweight durable and heat-resistant materials are in high demand.

Figure: SEM images of 15 wt.% PEEK aerogel gelled in DPA at (a) 10 kx and (b) 20 kx magnification, with (b) location indicated by red box in (a).

Advantages:

• Environmentally friendly processing using benign solvent (1,3-diphenylacetone)
• Direct 3D printing of high-performance PAEK aerogels
• Superior mechanical strength with unique strut-like morphology
• High surface area and tunable mesoporosity for advanced applications

Potential Application:

• High-temperature thermal insulation
• Catalyst support structures
• Lightweight aerospace components
• Gas filtration membranes