Fig. 1. Morphology of PEEK HP3 powder particles

Fig. 2. Schematics of samples. (a) Shape and size of samples; (b) forming direction and location of samples

Fig. 3. DSC curves for SLS PEEK HP3

Fig. 4. Aggregation structure of SLS PEEK. (a) Low magnification; (b) high magnification

Fig. 5. Tensile properties of SLS PEEK and IM PEEK. (a) Ultimate tensile strength; (b) tensile curve

Fig. 6. Flexural properties of SLS PEEK and IM PEEK

Fig. 7. Visualized CT data.(a) Scanning volume diagram; (b) cloud diagram of overall defect; (c) hemispherical defects; (d) boundary defects; (e) pore defects

Fig. 8. Microtopographies of hemispherical defects in visual CT. (a) 3D view; (b) top view; (c) side view; (d) front view

Fig. 9. Microtopographies of boundary defects in visual CT. (a) 3D view; (b) top view; (c) side view; (d) front view

Fig. 10. Microtopographies of pore defects in visual CT. (a) 3D view; (b) top view; (c) side view; (d) front view

Fig. 11. Statistic of defect characteristics. (a) Relative quantity distribution; (b) sphericity distribution; (c) total volume distribution; (d) average volume distribution

Fig. 12. Statistic of porosity distribution. (a) Relationship between porosity and printing height; (b) relationship between porosity and sample thickness

Fig. 13. Sintering and defect morphologies at different magnifications (XOY plane). (a)(b) Morphologies of powder sintering; (c)(d) morphologies of boundary sintering; (e)(f) morphologies of hemispherical defect

Fig. 14. Tensile specimens and fractures. (a) SLS PEEK defect area shown in Micro-CT; (b) SEM image of SLS PEEK fracture; (c) SEM image of IM PEEK fracture

Fig. 15. Regions of flexural failure. (a) Fractured surface; (b) ductile region; (c) initiation region (crack propagation direction is from bottom to top)