3D printing vacuum-grade supports for an ion mobility spectrometry vacuum chamber using engineering-grade filaments

Project Abstract

Over the past year in the research lab, we received a grant to build an ion mobility spectrometry (IMS) testbed, which was utilized in a special topics class in the spring 2026 semester. IMS rapidly separates ions on the millisecond timescale based on their mobility through a buffer gas. This data swiftly reveals the compound’s identity. Ion Mobility requires ions to fly under vacuum to eliminate air and gas to create a controlled, low-pressure, oxygen-free environment.

The testbed created in the fall 2025 semester was an approximately 7 L vacuum chamber that included multiple feedthroughs for power and gas flow. A challenge presented when constructing the chamber was that mounting items inside required custom mounting solutions. As a preventative for wires interfering with any future moving parts or obstructing electrodes used to move ions during analysis, routing wires in the vacuum chamber is necessary. These stabilizers must be a customized mount and vacuum-grade; the most common way to achieve this is by 3D printing. PEEK (polyether ether ketone) is considered the gold standard 3D-printed polymer for high-vacuum parts. This specialty material in an already machined and assembled form costs over $4,000/oz, about the same cost as gold per ounce. This leads us to explore other routes that are more affordable, such as 3D printing our own.

PEEK requires a specialty printer that can reach 450 degrees Celsius. These printers can cost anywhere between $6,500 and $30,000. So, more economical alternatives were investigated. Two polymers were found that were 3D-printable on basic printers and had low outgassing required for UHV. The first, Z Polymers Tullomer, is extremely affordable in comparison to advanced high-strength materials like PEEK and ULTEM, costing $15 per ounce. Built on the backbone of Kevlar, the material used in bulletproof vests, Tullomer is significantly stronger than PEEK and is overall superior for vacuum use. The second filament comparable to PEEK in outgassing performance and printability is Creamelt COC. This filament is cheaper than Tullomer and is even easier to print. The downside of using Creamelt COC is its lower strength capabilities compared to Tullomer. In this case, Creamelt COC would be explored as an alternative to Tullomer due to price and ease of printing. It will be compared to Tullomer on its ability to maintain support of cabling and electrodes in the vacuum chamber. Although both filaments show great promise based on low outgassing and ease of printing on basic printers, they still require demonstration of their feasibility as practical mounting/cable routing solutions for vacuum applications. They have been previously tested solely for material properties. This proposal aims to demonstrate they can be 3D printed and practically used under vacuum conditions. With these materials, we can demonstrate their ability to be used as structural supports for small cables and electrodes under vacuum, essentially acting as cable zip ties and clamps to replace expensive PEEK parts that cannot be customized and easily afforded.

Funding Type

Research Grant

Academic College

Jesse D. Jones College of Science, Engineering and Technology

Area/Major/Minor

Pre-med/Chemistry/Cell Biology

Degree

Bachelor of Chemistry

Classification

Senior

Name

Dr. Caleb Morris

Academic College

Jesse D. Jones College of Science, Engineering and Technology

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