3D printer for polycarbonate

What is a Polycarbonate?

Polycarbonate is a thermoplastic material originally derived from processed propane and other materials. Plastic is commonly used for medical devices, eyewear, and so much more. It’s also pretty popular for 3D printing!

In fact, polycarbonate filament is considered the single strongest filament material, achieving tensile strengths greater than ABS, PETG, and even Nylon. When tested, a clip 3D printed in polycarbonate was able to hold an incredible 685 pounds without breaking, while PLA and ABS both failed before 300 pounds. So next time you’re printing a gear or another model that will face physical stresses, definitely give PC filament a consideration.

But strength isn’t the only unique property of polycarbonate!

For instance, PC is a hygroscopic material. This means the plastic absorbs moisture from the air pretty rapidly. So, if you leave a spool of PC filament in a humid environment, it will soak it all in, leading to bubbling in the hot end and brittle prints. As such, it’s recommended to always store PC filament in a drybox or sealed container of some kind.

Similar to PLA, PC is also decently sensitive to UV light so it should only be used for indoor projects.  

Polycarbonate filament comes in a multitude of colors but is usually transparent as this is the natural color of the plastic. This makes PC a unique choice as it is one of a few filaments that you can use for printing transparent items like lamp shades.

Sadly, though, printing polycarbonate is no easy feat. 

We’ll talk more about how you can print PC in a later section, but it requires much more intensive hardware requirements than almost any other traditional filament material. And, even with the necessary hardware, you’ll have to fine-tune a slicer profile in order to achieve high-quality prints.

When To Use Polycarbonate?

Polycarbonate is perfect when you are in need of a strong or transparent material. That’s why PC is so popular for industrial applications that require a lot of strength, such as machinery guards, eyeglasses, and even bulletproof glass.

Similarly, in a 3D printing setting, you should use PC filament whenever you want a model to be super strong and durable. For example, if you’re printing a computer monitor stand, door hinge, or a gear for a robot, you’ll want all the strength you can get, and PC provides just that!

Sadly, though, you shouldn’t use PC for outdoor prints as the plastic won’t respond well to the UV light from the sun. So if you need a strong outdoor print, consider using PETG filament.

Also, you shouldn’t use polycarbonate filament when you want to print a display model, like a miniature or cosplay set. While you may want these models to be strong, PC isn’t the best at providing detail in 3D prints, so you should consider materials like PLA or ABS instead.

Advantages and Disadvantages of Polycarbonate 3D Printing

As mentioned above, there are numerous advantages when it comes to printing with PC. In addition to the material’s strength, heat resistance, and natural transparency, PC is also more durable, flexible, and less dense than other filaments.  

Transparency comes with its own advantages! The transparent nature of PC is helpful in printing and also serves as an aesthetic option. 

However, there are some things to look out for and consider such as printing machinery, print settings, and the surrounding environment before using PC. 

When printing with PC, there are several extensive hardware requirements. PC requires the use of a hot nozzle, heated bed, and an enclosed printing space. These requirements are necessary as PC is very sensitive to its surroundings and will not print properly unless all parts are correctly set.

Printing issues such as warping of the finished product and over-extrusion can arise if printing and storage requirements are not met. As mentioned earlier, PC is hygroscopic and will react negatively (usually swelling) when introduced to water directly or if there’s any water in the air. It is critical to keep your PC filaments and projects in dry areas. 

PC’s last disadvantage is its price. While it is a little steeper than other filaments, it is worth it in the long run for certain projects due to the strength and heat resistance PC has. Prices vary between brands and based on quality but they usually sit between $30 and $60 for a spool around 750 grams.

How to 3D Print Polycarbonate?

Printing with PC can be difficult if you don’t have the proper setup or settings met. However, once you have perfected the necessary requirements, the payoff is worth it. 

Your first step when printing with PC is to make sure the material is dry. The hygroscopic PC will warp if it was exposed to too much water before printing, so before you even touch your printer settings, make sure your filament was stored properly in a dry environment. 

Next, you need to look at the temperature of your nozzle. PC is extremely heat resistant, which is great for the final project but makes the printing process a little difficult. You want your nozzle temperature to sit between 300-310 °C to make sure the PC will flow properly, but of course, play around with your own setup to see what works best for you.  

After setting your nozzle temperature, it is time to adjust the bed temperature. Considering that the PC is already coming out extremely hot, it’s important that you make sure that the filament does not stick to the bed!! To do so, the ideal bed temperature ranges from 145-150 °C, but a consistent heat of 135°C is also acceptable if it is the most your printer can do. 

It is also important to have an enclosed printer to ensure that the ambient temperature around your printed model is high enough to ensure good layer-to-layer adhesion during the printing process.

There are some extra things to take care of before you start printing. Make sure to disable any cooling fans during the printing process as it can cause the filament to warp and have other negative responses. Also, just like other filaments, the first layer is the most important!! If your print settings are not met perfectly, the rest of your print can suffer. But PC is easily recyclable so don’t worry if your first layer isn’t ideal.

Factors to Consider When Choosing a 3D Printer for Polycarbonate:

If you’re still here, you’re probably interested in purchasing your own 3D printer. But don’t just buy any 3D printer because most aren’t equipped with the hardware necessary to print polycarbonate filament. In the mini-sections below, we’ve gone over the main features to look for on a 3D printer for printing PC, such as bed temperature, enclosure presence, and more!

Material Compatibility

The first and most important factor to look at in a 3D printer is its material compatibility. Usually, the manufacturer will list which filaments do and don’t work on the machine but don’t always trust this information. Instead, look in the reviews and on Reddit (or other forums) to see which filaments actual users were able to print on the machine.

Also, make sure to check the maximum nozzle temperature, as this is a big regulator for material compatibility. If the nozzle can’t reach and stay at the necessary temperatures for printing PC, then the printer can not actually print polycarbonate. Remember: you want a maximum nozzle temperature of between 260-310 °C if you want to print PC.

Bed Temperature

It’s crucial to check the printer’s maximum bed temperature and to have a properly heated bed. PC will stick to a bed that’s not properly heated, which can cause damage to your print and can even make it impossible to remove the print from the bed. The max bed temperature in most printers sits at 135°C. However, the optimal temperature for printing PC sits between 145°C and 150°C. Looking for or modifying a printer that can reach those bed temperatures can make or break a project. 

Enclosure

As we mentioned, an enclosure is also necessary for printing PC filament, as it keeps heat around your model and prevents air draft. Without one, your PC prints will be super brittle, contain low-quality detail, and have other issues.

As such, you should look for a 3D printer that has a built-in enclosure. However, you can also get a printer without one and then build or buy an enclosure for the printer afterward. This is what I like to do as it usually ends up being cheaper (especially if you DIY it), and gives you some customization abilities. Check out our article on the best enclosures here.

Build Plate

The bed’s material is just as important as its temperature. A Polyetherimide (PEI) sheet is the best printing bed option for PC. Painters tape or glue sticks will adhere permanently to the prints due to its high printing temperatures, so they are not viable options, but PEI is extremely heat resistant and has high-temperature stability– great for PC printing!!

Build Volume

Lastly, don’t forget about the build volume. You wouldn’t want to get a printer that’s perfect at everything but can only print super tiny models.

While there’s no single volume that’s good for everyone, it’s smart to think about the sizes of the models you’ll be printing and establish a minimum volume that you’re looking for. For example, when I look for a 3D printer, I don’t choose one unless it’s got at least 200 x 200 x 200 mm of print space.

Conclusion

Are you ready to start printing with PC now? While printing with polycarbonate may be intimidating due to the filament’s requirement for a perfect climate, don’t worry!  This is an opportunity to use this incredible material.

PC is extremely strong, durable, heat resistant, and unique to use. The main takeaway about printing with polycarbonate is the printing environment. Make sure to store your PC  in a dry environment, or it will swell and can ruin your print. Also, make sure your printer has the proper nozzle and bed temperature and is a properly enclosed space to create the best environment for the PC. 

Our recommendations from this selection of printers would vary based on what you want. If you’re looking for an enclosure for quality, the Prusa i3 MK3S+ is the best option for you. The CR-10S is perfect if you want an enclosure for build space and the Pulse XE is the go-to for any other feature you want, like automatic bed leveling. 

The feats of 3D printing are never-ending and, while a more difficult process, printing with polycarbonate only further proves that anything can be possible.

Ultimate Materials Guide - 3D Printing with Polycarbonate

Overview

Polycarbonate (PC) is a high strength material intended for tough environments and engineering applications. It has extremely high heat deflection, and impact resistance. Polycarbonate also has a high glass transition temperature of 150° Celsius. This means it will maintain its structural integrity up to that temperature, making it suitable for use in high-temperature applications. It can also be bent without breaking and is often used in applications where some minor flexibility is required. Most available Polycarbonate filaments contain additives that allow the filament to be printed at lower temperatures, so make sure to consult the guidelines for your specific brand of plastic.

Polycarbonate is extremely hygroscopic, meaning it will absorb moisture from the air, which will affect its printing performance and strength. It should be stored in air-tight, moisture-free containers after opening. It also requires very high temperatures for printing and will exhibit layer separation if printed at too low of a temperature or with excessive cooling enabled. Polycarbonate is frequently best printed on a machine that has an enclosed build volume and is capable of handling high bed and extruder temperatures.

• Impact resistant
• High heat resistance
• Naturally transparent
• Bendable without breaking

• Requires very high print temperatures
• Prone to warping
• High tendency to ooze while printing
• Absorbs moisture from the air which can cause print defects

Hardware Requirements

Before 3D printing with Polycarbonate make sure your 3D printer meets the hardware requirements listed below to ensure the best print quality.

Bed

Temperature: 80-120 °C
Heated Bed Required
Enclosure Required

Build Surface

PEI
Commercial Adhesive
Glue Stick

Extruder

Temperature: 260-310 °C
All-metal hotend required

Cooling

Part Cooling Fan Not Required

Best Practices

These tips will help you reduce the chances of common 3D printing issues associated with Polycarbonate such as warping, stringing, and oozing.

Use a Proper Build Surface

PEI is the best build surface for Polycarbonate. Standard build surfaces like blue tape and glue stick have adhesives that break down at the high temperatures required to print Polycarbonate. Build-tak can also be used but tends to permanently adhere to Polycarbonate at temperatures higher than 80°C, and can sometimes warp aggressively enough at this temperature to pull the Build-tak off the plate. PEI sheets consistently hold on to Polycarbonate at 110°C, without permanently adhering to the part. Once the bed cools down, the part usually self-releases, or can be easily removed with a spatula.

Adjust Settings to Prevent Stringing and Oozing

Due to the extreme printing temperatures and low cooling fan speeds required to print Polycarbonate, there is a high possibility of stringing and oozing with this material. To prevent this, try increasing the retraction distance and retraction speed. Simplify3D also includes a useful option called Coasting, which will automatically reduce the pressure in the nozzle right before the end of a segment to avoid oozing when moving to the next segment. This option can be enabled on the Extruders tab of your process settings. If your 3D printer can handle it, you can also try increasing the XY travel speed on the Speeds tab of your Simplify3D process settings. This allows the printer to make faster movements, which means less time for oozing. For other tips on how to prevent stringing and oozing, please refer to our Print Quality Guide which has an entire section dedicated to this issue.

Customize First Layer Settings

Due to the high warping tendency of Polycarbonate, the first layer is extremely important when printing with this material. From our research, the material seems to stick the best with slow thick extrusions on the first layer. We recommend using a first layer height of 100-150%, a first layer width of 12-150%, and a first layer speed of 15-30%. All of these settings can be entered on the Layer tab of your Simplify3D process settings. Additionally, setting the first layer to print about 30° hotter than the rest of the part can greatly improve first layer adhesion.

Smooth Top Layers

High print temperatures mean that extruded filament will tend to droop if it is unsupported. Solid Infill Layers should be printed slowly, at around 50% speed, so that they have the best chance of successfully bridging the spaces between infill lines. At least 4 top layers should be used, which will ensure that top layers are as smooth as possible. Infill percentage should generally be kept higher than 25% density to ensure support for these top layers. If a part needs less infill, in order to be lighter or use less material, extra top layers can be added to increase the likelihood of a solid top-most layer.

Calibrate your Bridging Settings

Similar to the point above, bridging segments can also be affected by the high printing temperatures of Polycarbonate. As the plastic is extruded in thin air between either side of the bridge, it will have a tendency to droop while it cools. Simplify3D added many new bridging features in Version 4. 0, so these can be used to customize exactly how the bridges are printed for the best results. We found that using a bridging speed multiplier of 40%, a bridging extrusion multiplier of 120%, and setting the bridging fan speed to come on at 25% offered a good starting point for most materials. You want to make sure the bridging fan speed stays at a low value, otherwise it has a tendency to cause warping and separation due to the rapid temperature change.

Pro-Tips

• If parts are overheating, curling, or showing signs of drooping when printing sharp overhangs, consider setting the fan to 0% for the first layer (to ensure good bed adhesion), but then increase the fan speed to 40% or below after about 4 or 5 layers.
• If some moisture has been absorbed by the material, try lowering the printing temperature to 280°C or below, which can help prevent artifacts or bubbles in the print from the moisture content.

Get Started with Polycarbonate

Now that you know the basics, you are ready to tackle your first print with Polycarbonate. Below are a few suggestions to help you get started.

Common Applications

• High-strength parts
• Heat resistant prints
• Electronics cases

Sample Projects

• Carabiner
• Platform Jack
• Coffee Sleeve

Popular Brands

• Polymaker PC Plus, PC Max
• Matterhackers Flameproof PC
• eSun ePC

Polycarbonate for 3D printing

Description

Polycarbonate is a thermoplastic in honeycomb form widely used as a durable substitute for conventional glass. In addition, polycarbonate has found use as a material for the manufacture of CDs, contact lenses, protective equipment (for example, bicycle helmets or glasses). The combination of transparency of polycarbonate and high strength (about 250 times higher than ordinary glass) makes it possible to produce even bulletproof glass.

Another advantage of polycarbonate is its high resistance to high and low temperatures - from -40 to 120°C. In addition, polycarbonate is prone to attenuation when exposed to open flame, contributing to fire safety, and resistant to acids.

Among the disadvantages of polycarbonate, one can single out a rather high hygroscopicity. Thread spools are recommended to be stored in dry places, and preferably vacuum-packed. In addition, polycarbonate is somewhat vulnerable to ultraviolet light, which leads to loss of strength over time, and is vulnerable to attack by petroleum products and organic solvents.

3D printing application

Polycarbonate printing example

Polycarbonate is rare in FDM printing due to certain technological difficulties, but is rapidly gaining popularity as technology improves.

Polycarbonate requires a fairly high extrusion temperature in excess of 300°C when printing at high speed.

Due to its high hygroscopicity, it may be necessary to dry the consumable immediately before printing.

To do this, it is recommended to keep the thread for 8-10 hours at a temperature of 70°C.

Otherwise, water vapor may be released during extrusion, clouding of the material and increased shrinkage, which increases the risk of deformation.

Even dry polycarbonate will require the use of a heated worktable up to 90°C-120°C.

It is recommended to use a polyimide film (Kapton) for better adhesion of the first layer to the worktable surface.

Printing examples with dry and slightly damp polycarbonate

Finding the right balance of extrusion temperature and print speed will be required to maintain transparency and avoid nozzle clogging and cracking.

Printing at 30mm/s will require heat up to approximately 265˚C, 285˚C at 60mm/s, 300˚C at 80mm/s and over 305˚C at 120mm/s. The glass transition temperature of polycarbonate is about 150˚C.

Polycarbonate threads are available in standard diameters of 1. 75mm and 3mm.

Polycarbonate Safety

Polycarbonate itself is safe, but the material typically uses BPA as the main raw material. Bisphenol A, in turn, is very toxic even in small volumes, up to the excitation of oncological diseases. Unfortunately, polycarbonates often contain residual Bisphenol A (albeit in extremely small amounts), which is released when heated. Accordingly, the use of polycarbonate products for storing hot food or drinks is not recommended. Limited bans on the use of polycarbonate in food packaging have already been introduced in Canada and the EU, and are being considered in the US. We recommend that you print in a well-ventilated area.

Go to the main page of the Encyclopedia of 3D Printing

The Ultimate Guide to Polycarbonate 3D Printing

Contents

• 1 What is polycarbonate?
• 2 How strong is polycarbonate as a 3D printing material
• 3 What is the use of polycarbonate?
• 4 How can I print with a polycarbonate 3D printer?
  • 4. 1 1. Select a quality polycarbonate thread.
  • 4.2 2. Select a suitable polycarbonate 3D printer.
  • 4.3 3. Enclosed chamber for 3D printing.
  • 4.4 4. Effective adhesion to the frame
• 5 What are the limitations of polycarbonate 3D printing?
• 6 Can the Ender 3 print on polycarbonate?
• 7 Should I get polycarbonate 3D printing service in China?
• 8 Conclusion

polycarbonate is a thermoplastic compound known for its high strength and impact resistance. It is commonly used for demanding engineering applications as it can withstand any external force without breaking or corroding.

This thermoplastic material is also capable of withstanding high temperatures. At glass transition temperatures of up to 150°C, the material will still manage to maintain its physical and structural integrity.

In addition to heat-resistant polycarbonate, it is a fire-resistant material. Also, the fact that this material is an electrical insulator cannot be ignored.

Even with all these desirable characteristics, polycarbonate still bears minimal weight. It is lighter than most alternative materials that can be 3D printed.

As we mentioned, one of the key properties of polycarbonate is its strength. In fact, polycarbonate is commonly referred to as the "king" of 3D printing.

This is because it is the strongest material that can be 3D printed.

But how durable is this material compared to others? The strength of polycarbonate can be better understood by looking at the numbers.

In a test conducted by airwolf3d.com, various 3D materials were evaluated for their hardness. The main materials that have been tested include PLA, ABS, nylon and polycarbonate.

Each material was loaded with some weight that was attached to a hook.

Guess which material won? Polycarbonate won by a wide margin.

With a breaking strength of 7250 psi, the PLA material was able to lift the weight up to 285 pounds. ABS, which has a tensile strength of 4700, snaps into place when attached to the same weight.

Polycarbonate with a tensile strength of 9800 psi was able to lift the weight to 680 pounds without a click. No other material can lift such a weight.

I hope you now understand why polycarbonate is the "king" of 3D printing.

Strength, heat resistance and durability make polycarbonate an ideal material for a wide range of applications. Some of the uses for polycarbonate include:

- Automotive industry for the manufacture of car parts.

- In the construction of buildings and transport infrastructure

- For the construction of electrical and telecommunications equipment / appliances

- For the creation of digital storage devices such as Blu-Ray discs, DVDs like bottles, food containers, crates, etc.

How can I 3D print polycarbonate?

How hard can polycarbonate be 3D printed? There is no doubt that polycarbonate can give you a headache when it comes to printing it on other related products.

However, with the right people and the best 3D printer, this process can be easily completed without any problems. Of course, the correct procedure must be followed when printing on polycarbonate media.

Like other 3D printing media, it all starts with choosing the right material. This is because low quality filament can result in poor print quality.

Beware of cheap polycarbonate threads. While they may seem flawless, they can cause serious problems when printed with a 3D printer.

Some polycarbonate manufacturers tend to produce filaments with fillers and additives. Such additions will affect the 3D printing process and even degrade the quality of the final product.

Inferior polycarbonate has air pockets that can cause the 3D printer to jam or clog.

Don't be tempted by low prices. Instead, take your time to carefully examine the 3D printing material.

Variable diameter polycarbonate filaments can end up with drops, extrusions and other imperfections in the final print.

So how do I find good quality 3D polycarbonate filament?

The surest option is to buy polycarbonate from a trusted manufacturer. Thus, you can be sure of the quality of the resulting 3D materials.

You should also take the time to check with the manufacturer about the filament before buying it. Ask them if their polycarbonate contains any additives or other chemicals.

If the situation permits, take several thread samples to evaluate their quality.

After all, your ultimate goal of 3D printing on polycarbonate is to preserve the structural integrity and beauty of the material.

Once you have selected a quality polycarbonate 3D printing filament, the next step is to find the right 3D printer.

Given the physical, chemical and structural properties of polycarbonate, you can't just use any 3D printer to do the job. The printer must have certain attributes that make it suitable for polycarbonate 3D printing.

For example, the printer must be able to withstand very high temperatures. It should also have a closed chamber in which the polycarbonate material will be heated.

For years, having the right printer has always been a major barrier to 3D printing. This is because most 3D printers cannot withstand the extremely high temperatures required to print polycarbonate filaments.

The highest temperature threshold for successful printing on polycarbonate is between 290°C and 320°C.

This automatically means that the few printers that can be used to print on this material are expensive. In fact, you will rarely find one that costs less than $50,000.

The good news is that you don't have to bear all these costs. You can easily outsource this service to a 3D polycarbonate production company and they will do all the work for you.

For example, Roche Industry has a suitable 3D printer. You must provide the thread and we will print for you.

Again, having the right printer for the process is not enough. 3D printing on polycarbonate must be done in a closed chamber.

The purpose of the chamber is to ensure proper temperature control so that the final product is free from defects.

Temperature control prevents defects such as cracks and deformations of the product.

In addition to proper heat management, polycarbonate 3D printing also requires proper adhesion to the substrate. This is the hardest part when it comes to printing on high quality materials like polycarbonate.

The fact that polycarbonate tends to warp when processed leaves you no choice but to pay attention to the adhesive properties of the bed.

At Roche Industry, we ensure that these four essential aspects of polycarbonate 3D printing are given the close attention they deserve.

While 3D printing is the best way to make polycarbonate items, it also has some limitations.

Here are some of the disadvantages of this method:

- Printing on polycarbonate material requires extremely high temperatures compared to other materials.

- Polycarbonate is prone to warping. This means that all conditions for printing must be ideal, otherwise deformation will be inevitable.

- High chance of leaking liquid polycarbonate during printing.

- Polycarbonate - hygroscopic material. It will probably absorb some moisture during the printing process. This can lead to 3D printing defects.

How can I remove these restrictions?

The best solution is to seek the services of the best polycarbonate 3D printing company in China. They have the right tools and conditions to achieve the best results.

Reliable 3D polycarbonate companies also have specialists who can handle the entire process with the utmost precision.

People who can't afford polycarbonate 3D printers usually prefer to use the Ender 3, which is a device commonly used for 3D printing.

While it can still be used for 3D printing, you need to take extra strict measures to get the best results from it.

For polycarbonate, this may be more difficult due to the nature of the material. For example, reaching very high temperatures with the Ender is no walk in the park.

Due to some deficiencies, the final product may have many defects. So it's safe to say that you shouldn't rely entirely on the Ender 3 for polycarbonate 3D printing.

If you want to make parts and products from polycarbonate material. This leaves you no choice but to print this material in 3D.

Should I pay for a polycarbonate 3D printing service or do the work myself?

As we have seen, printing on polycarbonate material is a complex technical process. This is also very expensive.

This is also a risky business, as you may end up doing the process incorrectly, resulting in wasted material.

It is best to outsource this service to reliable polycarbonate printing companies in China.

You will save a good amount of money, especially if you get an affordable polycarbonate 3D printing service.

As we have seen, anything can be obtained from polycarbonate. All you need is an elaborate polycarbonate 3D printing service.

If you need this service, we are here to help. Roche Industry is specialized in providing polycarbonate precision 3D printing services in China. Contact for a free offer.

Links to related sources:

Handbook: Everything you need to know about PETG

PETG vs ABS: What's the difference?

PETG vs PLA: What's the difference?

Polycarbonate vs Acrylic: What's the difference?

Nylon vs Polyester: What's the difference?

Trivex vs Polycarbonate: What's the difference?

White Paper: The Complete Guide to Thermoforming

All You Need to Know About PVC Pipe Sizes

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