Enhancing Mist Pump Efficiency and Durability with Additively Manufactured PEEK Bushing

A failed pump bushing in a high-stress legacy mist pump system presented us with another opportunity to demonstrate additive manufacturing’s potential. Employing carbon-reinforced PEEK via Fused Filament Fabrication, our team reverse engineered the legacy part and manufactured a replacement with design enhancements such as optimized counterbore depth, reinforced walls, and improved thread design. The new bushing not only restored operations but enhanced system performance and durability.

This case study exemplifies additive manufacturing’s advantage in replacing legacy components in a timely manner, while improving uptime. It also highlights the sustainability benefits of additive manufacturing: reduced material waste, localized production with minimal carbon footprint, and extended component lifecycle—all supporting a transition toward more environmentally responsible maintenance approaches.