(506) 2240-6804
High temperature 3d printing
High-Temperature 3D Printers | Vision Miner
Designed for PEEK, ULTEM, and other High-Performance Polymers, these machines are all open-filament, open-source and cutting-edge in their respective categories.
Which Printer Do You Need?
With dual independent extruders capable of 500ºC, an actively-heated chamber reaching 90ºC, and a triple-motor, true-self-leveling 200ºC bed, coupled with the fully open material system, the 22 IDEX is unlocking the potential of in-house additive manufacturing, at a price that disrupts everything the industry has seen before.
LEARN MORE
High-Quality Selective Laser Sintering 3D Printers -- with 9 different polymers to choose from, and a totally open material platform, the Sinterit line of SLS machines are the best we could find on the market, and now, they're available to you and your business.
LEARN MORE
The AON-M2+ is a high temperature, industrial 3D printer that can fabricate the highest performance thermoplastics. Print bigger and better with its actively heated build chamber and large build volume.
Choose from materials that can replace metals, with properties that can withstand the harshest operating conditions.
Avoid getting tied down with costly proprietary polymers, and experience the freedom of choosing between leading chemical companies.
AON M2 ⤑
Essentium is fundamentally changing how things are made. As innovators in both materials and production platforms, Essentium is disrupting traditional manufacturing processes by bringing strength and speed together, at scale, with a no-compromise material set.
At 5-15x faster than the competition, Essentium's High Speed Extrusion (HSE) 3D Printing Platform is built to transform manufacturing floors and solve the issues of strength, speed and cost. You can finally harness the power of 3D printing at scale without sacrificing accuracy or speed.
Did we mention it's all Made in the USA?
ISO 9001:2015 and AS9100D Certified + ITAR Registered
Essentium HSE 180•S Platform
The Intamsys Funmat HT Enhanced is designed specifically to 3D print high-performance functional materials like PEEK, PEI and PPSU, in addition to a broad range of engineering thermoplastics.
Users can achieve 50-micron, high-resolution, industrial-quality 3D printing with the Intamsys Funmat HT.
The Enhanced version includes a new build platform, ceramic-glass build plates, updated extruder design, auto bed-leveling, independent motor drivers, and more.
FUNMAT HT ⤑
The FUNMAT PRO 410 is an industrial additive manufacturing 3D printer designed for PEEK, PEI & PEI Blends, PPSU and other High-Performance Polymers.
For the very first time, the INTAMSYS FUNMAT PRO 410 features a dual extruder which operate in a large 305 x 305 x 406 mm build chamber (12 x 12 x 16 inch).
FUNMAT PRO 410 ⤑
This printer has been discontinued by Cincinnati, Inc. We have kept this page live for archival purposes.
The SAAM High-Temperature 3D Printer by CINCINNATI can print with virtually any material, from PEEK to Nylon, at a resolution of 11 microns.
Reaching temperatures of 500°C in the printing head, 250°C heated bed, and a heated chamber capable of reaching 160°C, the SAAM HT can print nearly any material on the market.
SAAM HT is optimized for fabrication of tooling, fixtures, prototypes, and functional parts.
Cincinnati SAAM HT ⤑
MAAM (Medium Area Additive Manufacturing) is an industrial sized additive machine built for production manufacturing. A rigid welded frame, CNC controls, and the latest extruder technology are combined in this machine to print parts accurately and consistently at speeds that are unmatched in the filament 3D printer market.
Its dual print head allows for multi-material printing. Its open source material solution, along with its temperature capabilities in the chamber, print bed and nozzle allow for 3D printing the industry’s most highly engineered thermoplastics, even PEEK and ULTEM™.
Cincinnati MAAM ⤑
Cincinnati Incorporated, in partnership with Oak Ridge National Labs, has developed the world's first industrial size 3D printer and taking additive manufacturing to a large scale.
BAAM (Big Area Additive Manufacturing) is an industrial sized, additive machine.
The machine uses the proven design and technology from our laser platform, including the machine frame, motion system, and control, and has been adapted with an extruder and feeding system. BAAM was designed to allow 3-D printing to be used for production manufacturing. The size and speed allow large parts to be made quickly. The ability to use commodity thermoplastic materials means that the cost per part will be reasonable. By designing a system with an open architecture for material vendors, material costs will be kept lower and with more options.
REQUEST QUOTE
The Colossus 3D printers are the first FGF printing systems designed with a special accent on materials for furniture, construction applications and large size 3D objects. It also prints with recycled materials, combining cutting-edge technology to give plastics a second life.
Colossus wants to break down the barrier of entry for designers to sell not only their designs but make their vision into objects without current limitations.
They also develop 3D technology for the commercial markets, like Furniture, Art, Molds, Automotive, prototyping, small series designs --everything is possible.
REQUEST QUOTE
2022 Guide to PEEK 3D printers (and PEKK, ULTEM/PEI)
Introduction
PEEK, like PEI (ULTEM) and PEKK, is a high-performance polymer (a.k.a. “ultra polymer” and sometimes “super polymer”) that is able to maintain its mechanical properties in challenging environments. Its continuous use temperature (CUT) can go over 250°C, and it is resistant to almost all chemicals except for nitric and sulphuric acids. For decades, this high-performance thermoplastic has been used in demanding industries such as aerospace, oil and gas, and more.
The 3D printing of high-performance polymers like PEEK is, however, a challenge. It requires a high-temperature extruder and a heated chamber – among other tightly monitored elements – above and beyond what standard FFF 3D printers offer.
And whereas the PEEK 3D printer market used to be a niche with very few players, today, many manufacturers claim that their printers are suitable for PEEK and PEI 3D printing. Aniwaa’s 3D printer catalog lists over 90 high-temperature 3D printers!
But boasting high-temperature extruders and heated chambers is often not enough. Thus, our goal here is to select high-temperature 3D printers that stand out from the rest, and not only in terms of hardware. We also take into account a range of factors such as manufacturer maturity, feedback from our network, availability, and distribution.
Of course, this doesn’t mean they’re the only ones out there, but they are some of the most reliable solutions for high-performance polymer AM (additive manufacturing). We mention a few cost-effective options and industry-specific machines in separate sections so as to provide a comprehensive overview nonetheless.
We work with a large number of distributors and brands worldwide– contact us for a personalized recommendation based on your project and location.
High-temperature 3D printers 2022: our selection
The table below recaps our selection of some of the best PEEK 3D printer options. The goal is to provide a quick, visual overview of the market; there are of course numerous other factors to take into account (certifications, software, customer service, …) to get the full picture for each solution and eventually make the right choice.
| Brand | Product | Build size | Country | Price Approximate starting prices based on supplier-provided information and public data. Prices may vary by region, over time and do not include additional products or services (taxes, shipping, accessories, training, installation, …). | |
|---|---|---|---|---|---|
| INTAMSYS | FUNMAT PRO 410 | 305 × 305 × 406 mm12.01 × 12. 01 × 15.98 in | China | $ 25,00025 412 €22,176 £3,726,400 ¥ | Quote |
| Apium | P220 | 220 × 175 × 160 mm8.66 × 6.89 × 6.3 in | Germany | $ 29,00025 000 €25,724 £4,322,624 ¥ | Quote |
| 3DGence This brand is a certified partner from our network. | INDUSTRY F421 | 380 × 380 × 420 mm14.96 × 14.96 × 16.54 in | Poland | $ 50,00050 000 €44,352 £7,452,800 ¥ | Quote |
| AON3D This brand is a certified partner from our network. | AON M2+ This product has been reviewed by our team. | 450 × 450 × 565 mm17.72 × 17.72 × 22.24 in | Canada | $ 59,40060 380 €52,690 £8,853,926 ¥ | Quote |
| miniFactory | Ultra | 330 × 180 × 180 mm12.99 × 7.09 × 7.09 in | Finland | $ 65,00065 000 €57,658 £9,688,640 ¥ | Quote |
| 3ntr | Spectral 30 | 300 × 300 × 300 mm11. 81 × 11.81 × 11.81 in | – | $ 110,000111 814 €97,574 £16,396,160 ¥ | Quote |
| Stratasys | Fortus 450mc | 406 × 355 × 406 mm15.98 × 13.98 × 15.98 in | – | $ 149,000116 000 €132,169 £22,209,344 ¥ | Quote |
| Roboze | ARGO 500 | 500 × 500 × 500 mm19.69 × 19.69 × 19.69 in | Italy | upon request | Quote |
Expand to see more specs
Note: There are over 90 printers that are supposedly capable of 3D printing PEEK and other high-performance materials. This is a shortlist of what we believe to be some of the best PEEK 3D printers on the market.
The products in the table are ranked by price (low to high).
| Brand | Product | Build size | Build volume | Extruder temp. | Build plate temp. | Build chamber temp. | Country | Price Approximate starting prices based on supplier-provided information and public data. | |
|---|---|---|---|---|---|---|---|---|---|
| INTAMSYS | FUNMAT PRO 410 | 305 × 305 × 406 mm12.01 × 12.01 × 15.98 in | 37.77 L | 450°C | 160°C | 90°C | China | $ 25,00025 412 €22,176 £3,726,400 ¥ | Get a quote |
| Apium | P220 | 220 × 175 × 160 mm8.66 × 6.89 × 6.3 in | 4.77 L | 540°C | 160°C | 180°C | Germany | $ 29,00025 000 €25,724 £4,322,624 ¥ | Get a quote |
| 3DGence This brand is a certified partner from our network. | INDUSTRY F421 | 380 × 380 × 420 mm14.96 × 14.96 × 16.54 in | 60.65 L | 500°C | 180°C | 195°C | Poland | $ 50,00050 000 €44,352 £7,452,800 ¥ | Get a quote |
| AON3D This brand is a certified partner from our network. | AON M2+ This product has been reviewed by our team. | 450 × 450 × 565 mm17.72 × 17.72 × 22.24 in | 114.41 L | 500°C | 200°C | 135°C | Canada | $ 59,40060 380 €52,690 £8,853,926 ¥ | Get a quote |
| miniFactory | Ultra | 330 × 180 × 180 mm12.99 × 7.09 × 7.09 in | 10.69 L | 480°C | 250°C | 250°C | Finland | $ 65,00065 000 €57,658 £9,688,640 ¥ | Get a quote |
| 3ntr | Spectral 30 | 300 × 300 × 300 mm11.81 × 11.81 × 11.81 in | 27 L | 500°C | 300°C | 250°C | – | $ 110,000111 814 €97,574 £16,396,160 ¥ | Get a quote |
| Stratasys | Fortus 450mc | 406 × 355 × 406 mm15.98 × 13.98 × 15.98 in | 58.52 L | 450°C | 350°C | 350°C | – | $ 149,000116 000 €132,169 £22,209,344 ¥ | Get a quote |
| Roboze | ARGO 500 | 500 × 500 × 500 mm19. 69 × 19.69 × 19.69 in | 125 L | 550°C | – | 180°C | Italy | upon request | Get a quote |
Prices may vary by region, over time and do not include additional products or services (taxes, shipping, accessories, training, installation, …).
Below, we mapped these PEEK 3D printers by price and chamber temperature. Again, there are other factors to take into account (manufacturer maturity, customer service, warranties, material choice, certifications, etc.) – this is just a preliminary, simplistic view of the high-temperature 3D printer market.
An overview of our 2022 PEEK 3D printer selection
In this section, we give some more context and information about each high-temp 3D printer from our selection.
INTAMSYS has been producing high-temperature 3D printers for several years. The FUNMAT PRO 410 is one of the company’s most affordable solutions along with the FUNMAT HT.
This entry-level solution for high-performance polymer 3D printing features a large build volume, a dual extruder, and sensor-assisted bed leveling.
Contact manufacturer Get a quote Add to comparison
This German 3D printer provides a smaller build volume than others on our list, but its adaptive heating system is an uncommon characteristic that is essential for compliance with very tight tolerances.
Repeatability is definitely one of the Apium P220’s main advantages, and makes it one of the best PEEK 3D printers on the market.
Contact manufacturer Get a quote Add to comparison
AON3D is a Montreal-based AM hardware, software, and material company that aims to make industrial 3D printing accessible to businesses. Its AON M2+ printer offers a precision-controlled 3D printing environment for high-performance polymers.
The AONM2+ is one of the only high-temperature 3D printers to offer independent dual extrusion. In addition, it offers one of the largest build volumes in its category. This 3D printer has been used to produce parts with ultra polymers for the Peregrine moon lander.
Contact manufacturer Get a quote Add to comparison
3DGence’s Industry F420 is an enlarged, upgraded version of the Industry F340, a 3D printer for PEEK that we’ve featured before.
It boasts even higher temperatures, as well as a new filament chamber that can hold up to four spools and keep them heated at 50°C.
Contact manufacturer Get a quote Add to comparison
Paired with miniFactory’s AARNI process monitoring system, the Ultra is able to deliver certifiable 3D printed parts.
It’s equipped with an annealing system as well, making it possible to enhance part quality and dimensional stability. The printer’s heated filament chamber keeps materials prepped at 120°C.
Contact manufacturer Get a quote Add to comparison
Italian manufacturer 3ntr has been producing high-temperature 3D printers for several years, but the Spectral 30 is their first printer to be officially dedicated to PEEK and PEI.
With its quadruple 500°C extruders, 300°C build plate, 250°C build chamber, and 110°C filament bay, the Spectral 30 is hard to match. This 3D printer also features a door safety feature: the door is locked until the temperature has descended to 55°C.
Contact manufacturer Get a quote Add to comparison
Stratasys produces some of the best professional and industrial printers on the market.
While their systems used to be limited to Stratasys-branded materials, they’re now (h3 2022) compatible with Stratasys-validated materials from other brands. Materials that have not been validated by Stratasys can also be used, but with an annual Open Material License subscription.
The material choice for the Fortus 450mc includes ULTEM 1010 and ULTEM 9085, and a range of ABS, PC, ST, PEKK and PA-based filaments. Stratasys markets the Fortus 450mc as a reliable machine that doesn’t require particular skills or advanced knowledge of 3D printing.
Contact manufacturer Get a quote Add to comparison
The Roboze ARGO 500 is an industrial-grade solution from Roboze, an Italian manufacturer that has dedicated itself to the high-temp 3D printer sector since 2014. The ARGO 500 sits at the middle of the company’s ARGO production series, in between the smaller ARGO 350 and larger ARGO 1000.
Roboze’s high-temperature 3D printer controls, analyzes and stores all of the information and parameters from each print in its onboard, industrial B&R computer.
This means that each part can be certified.
Contact manufacturer Get a quote Add to comparison
There are a few other brands that produce good quality PEEK and PEI printers, which almost made it to the main list. However, we didn’t include them for different reasons (e.g. product not yet released, limited distribution network, and/or technical specs or features not up to par with the rest of the list, etc.).
Tip: Use our 3D printer catalog to see the full list of high-performance polymer 3D printers!
Alternative PEEK 3D printers for specific needs
While the high-temperature 3D printers from our selection are excellent options for most applications, some use cases require more specific solutions. Here are a few examples.
Medical PEEK 3D printing
PEEK is a great contender for medical applications. It is namely used for long-term medical implants, as medical-grade PEEK is biocompatible and highly resistant.
With certified materials and certified AM systems, it is possible to produce certified medical parts.
Another notable benefit is that PEEK implants, in contrast to metal implants, don’t interfere with scanning machines (MRI, CT, x-rays, …).
The three main medical PEEK 3D printer brands are Apium, VeraShape, and Kumovis.
- Apium M220
- VeraShape VSHAPER MED
- Kumovis R1
Cost-effective PEEK printers
If you have a smaller budget but you’re willing to spend more time on tweaking and adjusting, there are more affordable options out there such as:
- CreatBot PEEK-300
- IEMAI MAGIC HT PRO
- INTAMSYS FUNMAT HT
Affordable PEEK printer prices can start from around $5,000. They are able to print PEEK, but the resulting quality may not meet your standards, especially in terms of repeatability. These machines are however more than capable of printing other engineering-grade materials.
Custom PEEK 3D printers
Some brands like Tobeca, Qualup (SpiderBot), or Hyrel 3D aren’t widespread but offer interesting, tailored solutions for PEEK 3D printing.
Their custom PEI/PEEK 3D printers can be suitable for R&D applications or any case where specific sizes and components are needed.
Large, industrial PEEK 3D printing systems
Warpage is often an issue when 3D printing large parts. Hence, 3D printing large parts with a thermoplastic as challenging as PEEK is double the risk.
Some manufacturers that are specialized in large-scale 3D printers claim that they are also able to print PEEK (e.g. Cincinnati, BigRep, CEAD, Cosine Additive, etc.).
We know the PEEK printer market like the back of our hands. Contact us now to save time and receive expert advice based on your needs and budget. We’ll put you in touch with the right manufacturer or PEEK 3D printer distributor near you.
Key characteristics and properties of PEEK
Pros of PEEK filament
PEEK is a dimensionally stable, semi-crystalline thermoplastic. It can tolerate significant changes in temperature, humidity, and other conditions.
Here are some of the main benefits of PEEK:
- Useful operating temperature (a.k.a. continuous use temperature) of up to 250°C-260°C
- Low flammability and low levels of toxic emissions during combustion
- High mechanical strength
- Low moisture absorption; water and steam resistant
- Chemical resistance (with exceptions)
- Biocompatible
- Lightweight
PEEK drawbacks
This material also has a few limits:
- Complex to 3D print
- PEEK is expensive
- Low impact strength
- Non-resistant to UV light
Alternative high-performance materials
PEEK isn’t the ultimate “one size fits all” material. In many cases, other engineering materials or fiber-filled materials (composites) can substitute the need for PEEK. Here are a few examples.
PEKK (Poly Ether Ketone Ketone): a good alternative to PEEK
PEKK and PEEK are both part of the same polymer family called PAEK (Poly Aryl Ether Ketone).
They boast similar properties in terms of strength, chemical resistance, and more. However, PEKK can be easier to 3D print than PEEK.
It is possible for filament manufacturers to tweak its melting point, and therefore generally requires lower temperatures. PEKK can also have a slightly higher glass transition temperature (Tg) than PEEK.
PEEK vs. ULTEM (PEI)
PEEK and ULTEM® (PEI) are quite similar, but have their differences:
- Cost: ULTEM® is more cost-effective than PEEK.
- Impact strength: PEI has lower impact strength than PEEK.
- Tensile strength: PEEK has higher tensile strength than PEI.
- Certifications: ULTEM® (especially the ULTEM® 9085 blend) has received numerous aerospace certifications and is easier to 3D print.
- Temperature resistance: PEEK features higher temperature resistance than PEI.
- Printability: ULTEM® is generally easier to 3D print than PEEK is.
What’s the difference between PEI and ULTEM?
ULTEM® is actually a family of PEI products that was patented and developed at General Electric in the 1980s. SABIC, a company based in Saudi Arabia, acquired GE’s Plastics Division several decades later and now manufactures ULTEM® in the form of resins or foam. 3D printing material providers then transform it into granulates, filament, etc.
Continuous fiber reinforcement
It is also possible to reinforce PEEK or PEKK parts with a continuous strand of carbon fiber. This makes it possible to benefit from high-performance material properties (e.g. chemical resistance) while bringing a drastic increase in part strength.
A PEEK printed part reinforced with continuous fiber on the Anisoprint PROM IS 500. Source: Aniwaa (Composer A4 review)Chopped fiber reinforcement (“filled” materials)
There are a number of “filled” material options.
A filled material is a material that has been reinforced with, for example, chopped fibers such as carbon fiber or glass fiber. These materials are considered composites and can be good alternatives in some cases (learn more about composites here).
Common examples of filled materials include PEEK-CF (a carbon-fiber-enforced PEEK) and PA-CF (carbon-fiber-enforced Nylon).
Main requirements for 3D printing PEEK and PEI high-performance polymers
High-temperature extruder
The melting point for PEEK materials is 343°C. This means that the extruder needs to be able to reach that temperature or higher. The hotend extruder must also be all-metal and be resistant to abrasion.
Heated print bed
To print PAEK high-performance polymers, a heated bed is mandatory, and it must be able to reach temperatures of 120°C at the very least. This ensures correct adhesion and overall 3D print quality.
Closed, heated chamber
PEEK is highly prone to shrinkage and warpage (sometimes called warping). Ideally (and this is especially important for larger parts), the chamber temperature should be able to go up to or over 143°C, which is PEEK’s glass transition temperature (Tg).
The team at Vision Miner explains heated chambers very well in the video below:
It is extremely important to be in control of these temperatures and to keep them constant, as fluctuations can easily affect print quality. However, these aren’t the only conditions for printing high-quality PEEK parts; post-treatment also plays a major role.
In order for PEEK to crystallize as well as possible – and thus for the printed parts to be as strong and stable as possible – the material must be cooled gradually.
Unlike PLA parts, which can be removed from the tray almost as soon as they are printed, waiting several hours for the temperature of a PEEK or ULTEM part to drop to room temperature is necessary. This avoids disturbing the material’s crystallization process.
Some PEEK printers provide precise control over the chamber’s cooling rate.
Applications for high-performance polymer 3D printing
PEEK and ULTEM® 3D printing is mostly useful for manufacturers requiring strong prototypes and/or end parts that can withstand extreme conditions, in a variety of industries.
Some manufacturers even present PEEK 3D printing as an alternative to 3D printing metal parts.
Aerospace, automotive and military
Being lightweight yet strong and resistant, PEEK and ULTEM® 3D printed end parts are increasingly popular in aerospace, automotive and military fields.
ULTEM® has actually been used in the aerospace industry for decades and is heavily certified for related applications (e. g. airplane interiors).
Oil and gas
Thanks to PEEK’s chemical resistance and impermeability, oil and gas manufacturers can use the material to 3D print air valves and other parts.
Medical implants
PEEK and PEI are biocompatible, and can therefore be used for implants or other medical use cases.
Semiconductors
With PEEK’s electrical integrity it is possible to 3D print flexible circuit boards, as well as wire and cable insulation.
Cost of PEEK and ULTEM (PEI) 3D printing
PEEK 3D printers and ULTEM 3D printer prices
Most PEEK-ready 3D printers are available at prices ranging from $25K to $150K, and can even go up to $250K. It might seem like a hefty price tag, but these professional additive manufacturing systems feature specific technology that is difficult to integrate into a machine.
However, some PEEK 3D printers under $10,000 do exist.
PEEK and ULTEM filament price
PEEK filament price
Polyetheretherketone (PEEK) material is among the most expensive plastics on the market: its price can range from about $400 to $700 per kilo.
ULTEM filament price
PEI, or ULTEM®, is a cheaper alternative to high-performance PEEK material. The cost per kilogram can vary from $150 to around $280.
PEEK 3D printer FAQ
What kind of material is ULTEM®?
ULTEM® is a kind of thermoplastic used for professional and industrial applications.
What is ULTEM® plastic?
ULTEM® plastic is Polyetherimide (PEI), a strong, resistant thermoplastic that boasts similar characteristics to PEEK while being easier to 3D print.
What is PEI 3D printing?
Professionals and industrials use PEI to produce strong prototypes or end-use parts.
What material is PEI?
PEI stands for Polyetherimide and is also known as ULTEM®, which is actually a brand manufactured by SABIC. This engineering thermoplastic is strong and resistant to extreme conditions, though less than PEEK.
What is PEEK plastic?
PEEK stands for Polyetheretherketone. It is a highly resistant material (extreme temperatures, chemicals, etc.).
High Temperature 3D Printing to the Masses / Sudo Null IT News
There is an impressive variety of thermoplastics that can be printed on consumer grade desktop 3D printers. But, despite this, most often users turn to polylactide (PLA) threads. This is not only the cheapest of materials, but also the easiest to work with. Its extrusion can already be carried out at a temperature of 180 °C, and good results can be obtained even without preheating the table. The disadvantage of PLA-printed objects is that they are relatively brittle and do not tolerate high temperatures well. For prototyping or printing low-stress components, PLA is great. However, many users quickly go beyond its capabilities. nine0003
Polyethylene terephthalate (PETG) is usually the next step. It is not much harder to work with compared to PLA, while it is more reliable and can withstand higher temperatures. In general, it is better suited for creating mechanically loaded parts. But if you need to make even stronger and more heat resistant parts, you can switch to acrylonitrile butadiene styrene (ABS), polycarbonate (PC) or nylon. And this is where the problems begin. These materials are extruded at temperatures over 250°C and closed chambers are recommended for best results. These printers are at the top of the budget range that hobbyists are willing to work with. nine0005
Industrial 3D printers like this one, the Apium P220, start at around $30,000. (PAEK, PEEK, PEKK). Components made from these plastics are suitable for aerospace applications as they can replace metal while remaining much lighter.
Such plastics need to be extruded at temperatures of around 400°C, and a sealed chamber is required for operation, the temperature in which constantly exceeds 100°C. The cheapest printers of this kind cost tens of thousands of dollars, and some models even cost six figures. nine0003
Naturally, not so long ago, the same could be said about all 3D printers. Once used only by well-equipped research labs, these machines now sit on the workbenches of hackers and hobbyists the world over. It is difficult to predict whether the same price-cutting race will start for high-temperature 3D printers, but the first steps to democratize the technology have already been made.
Engineering difficulties
Simply put, a machine that supports these so-called. "engineering plastics", you need to be a hybrid of a 3D printer and a stove. This, of course, is the main problem. The printer itself - of the type and quality we are accustomed to seeing on our desks - will not survive in such conditions. In order for a consumer printer to produce PEI and PEEK plastic parts, it needs to be seriously redesigned. This is exactly what NASA did with the LulzBot TAZ 4 in 2016. nine0003
LulzBot TAZ 4 redesigned to support high temperature printing
The first step was to design an insulated housing to fit the TAZ 4 and install a set of 35W infrared lamps for heating. Under such conditions, the printer's electronics would naturally overheat - so it had to be taken outside.
Stepper motors would also overheat. But instead of taking them out, the team at the Langley Research Center decided to build cooling shrouds on each of the motors through which the compressed air must circulate. nine0003
Like many desktop 3D printers, the TAZ 4 uses several printed components. Since they are ABS, they would quickly break down in a chamber designed to support PEEK. They were printed from PC, but even this material was not resistant enough for permanent use. In classic RepRap tradition, the team printed the last, third set of components on their most modified printer, in PEI plastic, commercially named Ultem.
Surprisingly, the team had no trouble changing the printer's nozzle to one that could extrude plastic at 400°C. The popular E3D-v6 extruder costs less than $100 and has been shown to be able to maintain this temperature. True, the team had to replace the thermistor with a better one, as well as edit the Marlin firmware so that it allowed it to reach high temperatures. For conventional printers, too high a temperature should cause an emergency shutdown. nine0003
Printing results from Ultem 1010 plastic on a redesigned LulzBot TAZ 4.
In the end, the NASA report indicated that the redesign of the LulzBot TAZ 4 was a complete success. They noted that an attempt to print PEI with infrared lamps turned off ended in failure - delamination and distortion of the model, which was to be expected. They did not specify the cost of the conversion, but given that at that time the TAZ 4 cost $2200, the entire project could cost 10 times cheaper than similar commercial proposals. nine0003
Starting from zero
A NASA experiment has shown that an existing desktop 3D printer can be converted to print with high-temperature engineering plastics, and quite inexpensively. But hardly anyone believes that this approach is the ideal solution. There are too many repetitive operations involved here, and NASA engineers had to abandon some of the decisions made by the LulzBot developers. Still, the experiment provided a valuable baseline for other projects built from scratch. nine0003
In September 2020, a team from Michigan Technological University demonstrated the Cerberus, an open-source, high-temperature 3D printer capable of creating items from PEI and PEKK, that costs as little as $1,000 to build. Without trying to adapt existing designs, the team started development from scratch, aiming for high temperature printing. All electronics are housed separately from the sealed chamber, which uses a kilowatt heating element to quickly raise the temperature in the chamber to operating temperature. nine0003
All stepper motors are also outside the chamber. Because of this, the kinematics become more complex than in desktop 3D printers, but Cerberus no longer requires a special motor cooling system.
Building a Cerberus is quite affordable for the aspiring hobbyist. It has a simplified circuit, ready-made control electronics based on the Arduino Mega 2560 and RAMPS 1.4, and the same E3D-v6 extruder as the TAZ 4. In addition, the team posted clear and detailed instructions for assembling the printer - this is not in the NASA report. meet. nine0003
Expanding possibilities
Whether it's NASA's redesign of the TAZ 4, or the new Cerberus-type circuits, it's clear that the technical capabilities of PEI and PEEK printing in the home workshop are already available for those who really need them. So far, it's not as easy as buying a $200 3D printer on Amazon, but if there is demand, cheaper machines based on the same principles will appear on the market. The situation is not much different from the current wave of affordable laser cutters hitting the markets in the past few years. nine0003
Fans all over the world print PPE
Is there a demand for such machines? A year ago, the answer might have been different from today. But in the fight against the coronavirus pandemic, there is a new demand for the rapid production of personal protective equipment (PPE) that no one could have foreseen.
print PPE that can be sterilized at high temperatures. The team believes that masks printed from PEKK can be reused rather than thrown away. nine0003
Components that can be printed and re-sterilized will obviously have other potential medical applications. A portable, low-cost machine capable of producing such components has the potential to save lives in places on the planet where supplies and equipment cannot be quickly accessed.
Critics of 3D printing have often said that the main disadvantage of these machines is that the reliability of the items they make rarely allows them to be used for anything other than rough prototyping. But when a $1,000 printer starts making aerospace-grade components, we seem to be moving toward a manufacturing revolution at an unprecedented rate. nine0003
Overview of high-temperature FDM plastics for industrial 3D printing
The scope of application of additive technologies is wide: on one extreme - desktop printers "only PLA", for decorative applications, on the other - installations for direct printing with metals, between them - equipment and materials in assortment. To understand what materials are needed to obtain a strong and lightweight part, we are moving from personal printing to industrial printing. PLA, ABS, SBS are consumables that are familiar to all printers. PETG, nylon, polycarbonate - rather exotic. But these are far from the most serious materials. nine0003
Where are superplastics needed?
Plastics with outstanding properties are very useful in space. No, it’s not yet possible to print a rocket engine out of plastic, the heat resistance is not even close to the same, but it is ideal for various parts around. An example is Stratasys and the "climate control" of Atlas V rockets. 16 printed parts instead of 140 metal parts - faster, lighter, cheaper. And this is not a theoretical project, it has already flown into space.
Another example is aviation. The flight altitude is lower, but the application is more massive. Here, too, there is a reason to reduce the mass of parts, switch to plastic where possible. It is used in the aircraft industry and direct metal printing, when it comes to engine components or fuselage frame parts, but less loaded structural elements, such as cabin ventilation and interior elements, are best made from plastic. This direction is being developed, for example, by Airbus. nine0003
We are descending from heaven to earth: here the mass is no longer so critical, other properties of engineering plastics are interesting. Resistance to aggressive chemicals and elevated temperatures, the ability to create structures inaccessible to classical methods. At the same time - a lower price, in comparison with metal printing. Printed products are used in medicine, oil and gas industry, chemical industry. As an example, a mixing block with a complex channel structure, made for illustration in a section. nine0003
Difference from conventional plastics
Why not launch PLA into space and make ABS air vents in aircraft cabins? A number of requirements are applied to engineering plastics related to resistance to high and low temperatures, fire resistance, mechanical strength. Usually all at once. So, it is undesirable to launch PLA “floating” when interacting with the environment or perfectly burning ABS into the sky. Now - to what, in fact, plastics are used in industrial printing using FDM / FFF technology. nine0003
Polycarbonate filaments
Polycarbonate is a common industrial plastic with high impact resistance and transparency, also produced for the needs of FDM printing. The material holds temperature better than ABS, is resistant to acids, but is sensitive to UV radiation and is destroyed by oil products.
Clear polycarbonate, PC
The operating temperature limit for polycarbonate products is 130°C. Polycarbonate is biologically inert, products made from it can withstand sterilization, which makes it possible to print packaging and auxiliary equipment for medicine. nine0003
- Stratasys PC, PC-ISO for Fortus printers. The first is general purpose, the second is certified for biocompatibility, for medical use.
- Intamsys PC;
- Esun ePC;
- SEM PC;
- PrintProduct PC;
ABS/PC
Polycarbonate/ABS alloy combines the sanding and painting capabilities of ABS with higher impact resistance and operating temperature. Retains strength at low temperatures down to -50 °C. Unlike pure PC, it is better applicable in cases where it is necessary to eliminate the layered structure of the part by grinding or sandblasting. Application: production of housings and elements of controls for piece and small-scale production, replacement of mass-produced plastic parts in equipment, parts for which have ceased to be produced. nine0003
- Stratasys PC/ABS;
- Roboze PC-ABS;
- SEM ABS/PC;
- BestFilament ABS/PC.
Polyamide based filaments
Polyamides are used in the manufacture of synthetic fibers, a popular material for laser selective sintering (SLS) printing. For printing using FDM / FFF technology, polyamide-6 (kapron), polyamide-66 (nylon) and polyamide-12 are mainly used. Common features of polyamide-based filaments include chemical inertness and anti-friction properties. Polyamide-12 is more flexible and resilient than PA6 and PA66. Operating temperature approx. 100 °C, some modifications up to 120.
First of all, gears are printed from polyamide. The best material for this purpose, which can be worked with on a regular 3D printer with a closed chamber. Abrasion resistance allows you to make rods, cams, sliding bushings. In the line of many manufacturers there are composite filaments based on polyamide, with even greater mechanical strength.
- Stratasys Nylon 6, Nylon 12, Nylon 12CF. The latter is filled with carbon fiber.
- Intamsys Nylon, PA6.
- Taulman Nylon 618, Nylon 645 based on PA66 and PA6 respectively. Nylon 680 is approved for use in the food industry. Alloy 910 is a low shrinkage polyamide alloy.
- PrintProduct Nylon, Nylon Mod, Nylon Strong;
- REC Friction;
- BestFilament BFNylon.
Moving on to the fun part
You can work with polycarbonate or polyamide on a regular 3D printer. With the filaments described below, it is more difficult, they require other extruders and maintaining the temperature in the working chamber, that is, you need special equipment for printing with high-temperature plastics. There are exceptions - for example, NASA, for the sake of experiment, upgraded the Lulzbot TAZ popular in the USA to work with high-temperature filaments. nine0003
Polyetheretherketone, PEEK
Working temperature of PEEK products reaches 250 °C, short-term heating up to 300 is possible - indicators for reinforced filaments. PEEK has two disadvantages: high price and moderate impact resistance. The rest is pluses. The plastic is self-extinguishing, heat-resistant, chemically inert. Medical equipment and implants are produced from PEEK, abrasion resistance makes it possible to print parts of mechanisms from it.
- Intamsys PEEK; nine0110
- Apium PEEK;
- Roboze PEEK, Carbon PEEK. The second is reinforced with carbon fiber.
Polyetherimide, PEI
aka Ultem. A family of plastics developed by SABIC. The characteristics of PEI are more modest than those of PEEK, but the cost is noticeably lower. Ultem 1010 and 9085 are Stratasys' primary materials for printing functional parts. PEI is in demand in the aerospace industry - the mass is much less compared to aluminum alloys. Operating temperatures of products, depending on the modification of the material, reach 217 ° C according to the manufacturer and 213 - according to the results of tests by Stratasys. nine0003
The advantages of PEI are the same as those of PEEK - chemical and temperature resistance, mechanical strength. It is this material that Stratasys is promoting as a partial replacement for metal in the aerospace industry, for drones, the manufacture of tooling for molding, the rapid printing of functional parts in pilot production.
The cooling system components for the Atlas V rocket and the plastic parts for the Airbus jetliners shown at the beginning of this review are made of Ultem 9085.
- Stratasys Ultem 1010 and 9085, for Fortus 450mc and 900mc printers.
- Intamsys Ultem 1010 and 9085;
- Roboze Ultem AM9085F;
- Apium PEI 9085.
Polyphenylsulfone, PPSF/PPSU
Another material that combines temperature resistance, mechanical strength and chemical resistance in its properties. Stratasys PPSF is certified for aerospace and medical applications. Positioned as a raw material for the production of auxiliary medical devices, it can be sterilized in steam autoclaves. It is used in the production of parts for laboratory installations in the chemical industry. nine0003
- Stratasys PPSF;
- 3DXTech Firewire PPSU.
Polysulfone, PSU
Less common than PPSU, similar physical properties, chemically inert, self-extinguishing. 175°C operating temperature, up to 33% cheaper than PPSU.
- 3DXTech Firewire PSU
Filament performance comparison
* Baked for 2 hours at 140°C.
** Apium PEEK 450 natural, no similar impact test results available. Temperature resistance is specified for unfilled PEEK.
Data shown for Stratasys filaments, excluding PEEK. If a range of values is indicated, then the tests were carried out along and across the layers of the part.
About Composite Filaments
Most FDM materials have composite versions. If we talk about PLA, then metal or wood powders are added to it to change the aesthetic properties. Engineering filaments are reinforced with carbon fiber to increase the rigidity of the part. The influence of such additives on the properties of plastic depends not only on their quantity, but also on the size of the fibers. If a fine powder can be considered a decorative additive, then the fibers already significantly change the characteristics of the plastic. By itself, the word Carbon in the name of the material does not yet mean outstanding properties, you need to look at the test results. For example: Stratasys Nylon12CF has almost twice the tensile strength, when tested along the layers, than Nylon12. nine0003
Exotic variant - implementation of continuous reinforcement from Markforged. The company offers a reinforcing filament for co-FDM printing with other plastics.
Other specific properties
Engineering plastics are not only high temperature resistance and mechanical strength. For housings or boxes for storing electronic devices, and in environments where flammable volatile liquids are used, materials with antistatic properties are required. In the Stratasys line, this is, for example, ABS-ESD7. nine0003
- Stratasys ABS-ESD7;
- Roboze ABS-ESD.
Conventional ABS is not UV resistant, limiting its outdoor use without a protective coating. As an alternative, ASA is offered, which has characteristics similar to ABS, except for the UV resistance.
- REC Eternal;
- SEM ASA;
- BestFilament ASA.
Original alternative
Plastic can replace metal in many areas, as it surpasses it in lightness, thermal and electrical insulation, resistance to reagents. But printouts from the best FDM filaments do not reach the physical indicators of metal products.
Chemical giant BASF offers Ultrafuse 316LX FDM filament with 80% stainless steel by weight. The part is printed on an FDM printer and then placed in an oven where the binder plastic is burned off and the metal is sintered. The part obtained in this way is much cheaper than the one made by direct metal printing. With an FDM printer and a suitable oven, no new equipment is needed at all. nine0003
Note that Virtual Foundry offers a similar solution - its Filamet, with bronze or copper powder, is baked in a similar way. The choice of metal hints at decorative rather than engineering applications.
AIM3D has its own implementation of this principle - the ExAM 255 printer does not work with filament, but with granules. This allows the use of raw materials for FDM printing, which are usually used in MIM installations, Metal Injection Molding. For sintering the part, the company offers an ExSO 9 furnace0. It is also possible to print with plastic granules, which is usually cheaper than using traditional filament.
Special machinery for engineering plastics
To recap. In a nutshell: the considered consumables differ from the usual materials in high printing temperature, which requires the use of special equipment, and serious heat resistance and mechanical strength of the manufactured parts.
