High temperature applications
Polycarbonate handles continuous use up to 110°C with exceptional strength, while ULTEM 9085 provides 170°C continuous use temperature with aerospace certification.
Considerations for High Temperature Applications
Heat Deflection Temperature - The temperature at which parts begin to deform under load. Critical for structural components.
Continuous Use Temperature - Maximum temperature for long-term operation without degradation.
Thermal Expansion - Materials expand when heated; design must account for dimensional changes.
Chemical Resistance - High-temperature environments often involve aggressive chemicals or UV exposure.
Top Material Recommendations
1. Polycarbonate (PC)
The gold standard for high-temperature applications:
- 110°C continuous use temperature
- Exceptional impact strength
- Excellent dimensional stability
- Optical clarity available
Best for
Limitations
2. ULTEM 9085 (PEI)
For extreme temperature applications:
- 170°C continuous use temperature
- Aerospace and medical certification
- Excellent chemical resistance
- Flame retardant properties
Best for
Limitations
AMFG - Certified ULTEM 9085 with full traceability.
Stratasys - Original ULTEM 9085 formulation with aerospace approval.
3. ASA (Acrylonitrile Styrene Acrylate)
For moderate high-temperature needs:
- 90°C continuous use temperature
- Excellent UV resistance
- Good chemical resistance
- Easier printing than PC
Best for
Limitations
UltiMaker ASA - Reliable formulation with good printability.
BCN3D Technologies ASA - Professional-grade with excellent layer adhesion.
3ddruckboss ASA - Cost-effective option with good thermal properties.
4. PEEK (Polyetheretherketone)
For ultimate performance:
- 200°C+ continuous use temperature
- Exceptional chemical resistance
- Biocompatible grades available
- Outstanding mechanical properties
Best for
Limitations
Required Equipment
All-Metal Hotend
- 300°C+ capability required
- Hardened steel nozzles recommended
- PTFE-free heat break
Heated Chamber
- 80-100°C for PC
- 120°C+ for ULTEM
- Full enclosure essential
Bed Preparation
- PEI sheets work well
- High-temperature adhesives
- Heated bed 80-120°C
Print Settings
Temperature Guidelines
- PC: 280-320°C nozzle, 80-100°C bed
- ULTEM: 370-400°C nozzle, 120-160°C bed
- ASA: 240-260°C nozzle, 80-100°C bed
- PEEK: 380-420°C nozzle, 120-180°C bed
Print Speed
- Slow speeds (20-40mm/s) for dimensional accuracy
- Multiple perimeters for strength
- High infill (40-80%) for thermal mass
Design Considerations
Thermal Expansion
- Account for expansion in tight-fitting parts
- Design joints with thermal movement
- Use datum points for critical dimensions
Support Strategy
- Minimize supports due to difficult removal
- Use soluble supports when possible
- Design for orientation to reduce overhangs
Wall Thickness
- Minimum 1.2mm walls for strength
- Multiple perimeters for better heat resistance
- Avoid thin sections prone to warping
Testing and Validation
Thermal Cycling
- Test temperature extremes in application
- Monitor dimensional stability
- Check for stress cracking
Long-term Testing
- Continuous exposure at operating temperature
- Mechanical property retention
- Chemical resistance verification
Cost Considerations
High-temperature materials are expensive:
- PC: $100-200/kg
- ULTEM: $500-1000/kg
- ASA: $50-100/kg
- PEEK: $1000-2000/kg
Factor in:
- Equipment requirements
- Failed print costs
- Post-processing time
Remember that high-temperature printing requires significant equipment investment and expertise. Start with ASA for moderate applications before moving to PC or ULTEM for extreme requirements.