The production of fine filaments using the melt spinning process needs considerable effort. A thermoplastic melt is stretched from the spinneret under a constant take-up speed. The high performance thermoplastic PEEK is solidified in the melt spinning process in a small distance and short time. Therefore, the fine PEEK filaments in the fibre formation zone underwent a high deformation and cooling rate. To make the melt spinning process stable and to produce the fine PEEK filaments, material properties and material behaviour are examined using on-line and off-line measurements. The fibre speed measured using Laser Doppler Anemometry and simultaneous temperature measured using infrared thermography enable both the strain rate and consequently the apparent extensional viscosity to be estimated. This provides the apparent extensional viscosity over the spinning line, which can itself show the structural development of PEEK fibres in the fibre formation zone, i.e. necking and solidification phenomena. The one-dimensional fibre formation model must include both procedural and material parameters. The heat transfer coefficient was estimated using the filament temperature measurement and showed a relatively high contribution of radiation and free convection in comparison to forced convection near the spinneret. The improved model of PEEK fibre formation gave a good agreement to both temperature and speed measurements, and also confirmed the high deformation rate effect on the extensional viscosity, which could be simulated with a properly generalised Newtonian constitutive equation. The end properties of the fibres, such as as-spun filament fineness, orientation (expressed using total birefringence) and total crystallisation (examined using DSC) are investigated in relation to different spinning conditions, i.e. take-up speed, throughput and the draw down ratio. The tensile test diagram results, measuring phenomena such as the elongation at break, tenacity, and the Young modulus of elasticity are also analysed in order to complete the correlation of the above-mentioned spinning conditions to the structural properties of as-spun fine PEEK filaments. The melt spinning of fine PEEK fibres under different spinning conditions is examined with the purpose of finding the optimum take-up speed and throughputs. Other spinning conditions, such as the temperature of melt processing, and the arrangement and diameter of the spinneret holes, are changed in order to make the process more stable. The recommendations for further study can be used to further examine some aspects of this work; however, this work presents a new concept for fine PEEK melt spinning supported by spinnability examinations under different spinning conditions and the improved model of fibre formation, which is also relevant for typical industrial processing applications.