PEEK Powder Grades Explained: Coarse, Fine and Ultra-Fine - Matching Particle Size to Coating, Molding and Additive Manufacturing

Time of issue:2026-09-14 10:45

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PEEK Powder Grades Explained: Coarse, Fine and Ultra-Fine - Matching Particle Size to Coating, Molding and Additive Manufacturing

The particle-size decisions behind coating quality, printability and press efficiency

PEEK powder is not a single product. The same polymer sieved to different particle sizes behaves completely differently in a spray booth, a press or a powder bed, and most coating and moulding defects we see trace back to the wrong grade rather than the wrong polymer. As the producer of coarse, fine and ultra-fine PEEK powder, here is how we match each grade to its process.

Coarse powder: compression molding and compounding

Coarse powder, roughly 100-300 μm, packs densely, flows freely and sinters efficiently under heat and pressure. It is the default for compression molding of rods, blocks and near-net shapes, and for feeding extruders in hot-melt compounding, where high bulk density shortens cycle time and reduces voids.

Fine powder: SLS printing and electrostatic coating

Fine powder of about 20-90 μm is the working range for SLS 3D printing, where a uniform layer must spread and recoat cleanly, and for electrostatic spray coating, where charge-to-mass balance controls film build on preheated metal. Uneven distribution here shows up as orange peel and print defects.

Ultra-fine powder: precision coatings and composites

Ultra-fine powder below 20 μm disperses into solvents and binders for thin-film coatings, adhesives and composite matrices, where a smooth defect-free film matters more than bulk flow. It needs careful handling: low bulk density and moisture pick-up call for sealed packaging and gentle transport.

Figure 1. Particle-size verification of PEEK powder during batch release.

Four parameters to check on every offer

Compare D50 and the full distribution, ash content, purity and batch-to-batch consistency rather than price per kilo. We supply each grade with a batch COA, sieving certificates and moisture-proof sealed packaging, and we hold retention samples so future lots stay identical to your approved one.

Table 1. Matching PEEK powder grade to process

Grade	Typical D50	Best suited to	Watch-outs
Coarse	100-300 μm	Compression molding, compounding	Rough films, poor atomisation
Fine	20-90 μm	SLS printing, electrostatic coating	Orange peel if distribution drifts
Ultra-fine	< 20 μm	Thin-film coatings, composites	Agglomeration, moisture handling

Work with the manufacturer

TS DOWREN manufactures and exports TPV, TPE, TPU and TPEE plus engineering plastics including PEEK, PSU/PPSU, PPS, LCP, PPA and PMMA to customers in over 40 countries. Share your application and target specification: we will recommend a grade, provide datasheet, COA and compliance documents, and arrange samples for moulding or extrusion trials. Reach us at www.dowren.com.

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