by Melissa Donovan
Three-dimensional (3D) printers reach higher temperatures than ever before to fuse filaments together, creating functional parts for real world use. The filaments themselves must be compatible with high temperatures.
Above: BigRep’s IPSO 150 printer’s chamber temperatures can achieve up to 180 degrees celsius and extruder temperatures reach 450 degrees celsius.
One example, BigRep announced in Summer 2024 its fused filament fabrication (FFF) printer, the ALTRA 280. It offers high-temperature capabilities by printing with materials like Ultem 9085 and polyetheretherketone (PEEK).
Also of note, the UltiMaker Factor 4, equipped with a new hardened steel nozzle, which is 0.6 millimeters and enables the printing of high-temperature, high-performance materials like the new UltiMaker PPS CF.
The FFF process isn’t the only additive manufacturing (AM) solution fit for high-temperature production, other 3D printing processes that handle high-temperature materials are powder bed fusion, pellet printing, selective laser sintering, binder jetting, and material jetting. This article primarily focuses on FFF.
Define High Temperature
As higher temperatures become more realistic due to advancements in both the printers and filaments that can withstand that heat, it’s important to define high temperature.
For FFF, Thomas Janics, managing director of HAGE3D, BigRep, says temperatures need to reach and maintain a certain number that will fuse thermoplastic filaments effectively. In regards to the company’s ALTRA 280 and IPSO 150 printers, chamber temperatures can achieve up to 180 degrees celsius and extruder temperatures reach 450 degrees celsius.
“In contrast to injection molding’s forced material injection and subsequent cooling, FFF builds objects layer by layer without mechanical pressure, relying on a heated environment for proper layer adhesion and uniform cooling. This method is crucial for producing robust parts with complex geometries, especially for demanding applications in industries like aviation and rail,” explains Janics.
Luis Rodriguez, senior applications engineer, UltiMaker, says some FFF 3D printers print at temperatures between 300 and 500 degrees celsius, which would allow them to print higher temperature, stronger, and more durable materials. UltiMaker’s UltiMaker Factor 4 offers a high-temperature print core that allows engineers to print up to 340 degrees celsius.
Unlocking Possibilities
Temperatures are rising in 3D printers because of the inherent advantages offered, including material flexibility.
“There are a few advantages to being able to print to higher temperatures. For example, it allows for printing high-performance materials that offer advanced material properties that can withstand extreme environments. This includes increased strength, stiffness, and durability, which are crucial for some functional parts, end use parts, or even tooling, in industries like automotive, aerospace, and manufacturing,” shares Rodriguez.
Janics believes 3D printing in higher temperatures “unlocks a new world of high-performance applications. For example, high-temperature thermoplastics have great properties and can be a solution for any type of application. Polypropylene (PP) is excellent at chemical resistance and is often used in injection molding because it’s affordable. For thermal resistance, Ultem would be the top choice. If you need robust jigs and fixtures, Carbon Fiber PA is ideal. For printed molds for thermoforming, polyetherketoneketone (PEKK) CF is a good option, and acrylonitrile butadiene styrene (ABS) with electro static discharge (ESD) properties works well for electronic parts. All these technical and high-performance materials require a heated chamber above 80 degrees celsius. This ensures consistent mechanical properties, better layer adhesion, and warp-free parts,” explains Janics.
Filament Options
Many high-performance filaments are accessible for these higher temperature printing scenarios.
UltiMaker’s PPS CF is flame retardant. It is a semi-crystalline thermoplastic material, reinforced with carbon fiber. The material has a temperature resistance greater than 230 degrees celsius. It offers a high-performing alternative to steel or aluminum for less-demanding parts.
Ultem 9085 is particularly of note. A high-performance polymer, it is ideal for aviation and rail applications due to its high heat resistance and mechanical strength. Janics also cites UL94 V0 for its flame retardancy and chemical resistance.
“For functional parts built for aircraft and helicopters, reducing weight is a big deal—high-performance polymers like Ultem 9085. For example, parts of ventilation systems need to be lightweight but also meet strict requirements like UL94 V0 flame retardancy and chemical resistance,” says Janics.
In addition, “polycarbonate, ABS, and PP are other high-performance materials that have high strength, impact, and heat resistance that can create robust, durable parts,” adds Janics.
ABS ESD is “lightweight and rigid, protects against electro static discharge,” says Rodriguez. Another filament option—PEKK-A, which offers higher mechanical, thermal, and chemical resistance, he adds.
These products are used to create a variety of end parts. “Examples include engine parts, ducting or exhaust components, or other parts for areas that need to withstand high heat; functional prototyping; electronics and other electrical components; jigs, fixtures, and tooling,” says Rodriguez.
BASF’s Ultrafuse high-temperature materials like its Ultrafuse PPSU is worth noting. It is inherently flame retardant and offers a short-term temperature resistance up to 220 degrees celsius.
Evonik’s INFINAM PEEK 9359 F filament is for industrial 3D printing of high-temperature, lightweight parts using FFF technologies. Compared to 3D printed stainless-steel parts, PEEK-based 3D printed objects are 80 percent lighter in weight and 30 percent tougher with excellent fatigue resistance making them applicable as a substitution to 3D printing metal.
Due to the superior wear resistance and low sliding friction of PEEK lightweight structural parts, they can be manufactured easily.
Lubrizol 3D Printing Solutions offers an expanding portfolio of ESTANE 3D thermoplastic polyurethane (TPU) for use in FFF 3D printers. Engineered to meet high-performance demands, TPU is used across a variety of applications. ESTANE 3D TPU F94A-055 OR HH PL in particular is designed to perform in high heat.
What’s on the Market
Here’s more information on both BigRep and UltiMaker’s FFF high-temperature 3D printers.
BigRep engineered the ALTRA 280 as a high-performance industrial powerhouse with an expansive build volume. HAGE3D, a company specializing in large format high-temperature machines that are part of BigRep through a planned acquisition, originally built the ALTRA 280. The machine delivers unmatched reliability with up to four state-of-the-art extruders, each with its own backup. Built on CNC technology with ball screws and servo motors, the ALTRA 280 3D printer is precise, large, and fast. Its high-temperature capabilities allow for peak-level 3D printing, making it ideal for demanding applications in industries like aerospace, defense, and automotive.
The UltiMaker Factor 4 3D printer offers a temperature-controlled build volume of 330x240x300 millimeters and uniform bed heating, ensuring consistent performance across the entire build plate. Designed for manufacturing and industrial sectors, it can print high temperatures with a new high-temperature print core that allows engineers to print up to 340 degrees celsius. This enables a broader range of high-performance, temperature-resistant, and durable materials. The machine efficiently uses the heated bed and actively controlled chamber airflow to manage the build volume temperature up to 70 degrees celsius, ensuring optimal material-specific processing conditions and consistent part quality wherever the 3D printer is located.
Heating Up
FFF is well suited for high-temperature builds as it relies on heat for proper layer adhesion. Manufacturers up the game by creating printers that can print at temperatures reaching up to 500 degrees celsius. With these achievements the possibilities of which filaments to print with grows.
Sep2024, Industrial Print Magazine
