A high-performance semi-crystalline thermoplastic polymer with excellent mechanical qualities, great thermal stability, resistance to the majority of common solvents, and strong biocompatibility is known as polyetheretherketone (PEEK). PEEK in phenylphenol (4PPH) solutions was used to create PEEK foams with regulated foam density using a high temperature thermally induced phase separation approach. PEEK that had been foamed was characterized in terms of its physical and mechanical characteristics, foam and bulk density, surface area, and pore shape. The influence of PEEK concentration and cooling rate was also looked into.

Because of their low production costs, superior mechanical qualities, and lightweight and durability, polymers are today among the most widely utilized materials in the world. These characteristics make it easier for them to be used in a variety of applications, including consumer goods, building materials, insulation, films, membranes, and more.

An HT-TIPS procedure was used to create high porosity PEEK foams with adjustable porosity. Investigated were the effects of cooling rate and polymer content. Two key conclusions may be derived from the findings: The demixing process is significantly influenced by polymer concentration. When PEEK concentrations in 4PPH are below 10 wt%, solvent solidification takes place before polymer demixing, whereas at higher polymer concentrations, solution gelation brought on by PEEK crystallization occurs before solvent crystallization. PEEK from 4PPH solutions crystallizes over a longer period of time and with higher crystallinity in our foams, which results in densities of substantially higher skeletal PEEK (1360–1380 kg/m3) and elastic moduli of up to 125 MPa (as well as crush strengths).