Heat-Resistant 3D Printing Materials Guide - Formlabs

The two most common materials for FDM printing are PLA and ABS. Of the two, ABS offers higher heat resistance. There are also other more heat-resistant filaments available, however, these are often harder to print with or require specialized industrial 3D printers.

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PLA

PLA is the most common plastic material for filament 3D printers — it’s low cost,  has a very simple workflow, and comes in many colors, making it appealing to the hobbyist and K-12 education market. Standard PLA has a relatively low heat resistance, with an HDT of around 50 ºC at 0.45MPa. Therefore, for those looking to preserve the ease of use while being able to quickly and easily print heat-resistant PLA parts, many manufacturers offer a PLA material with additives that improve its heat resistance. Additionally, some workflows recommend an annealing step — meaning finished parts are reheated to further crystallize their structures and prevent creep or slow deformation when under strain.

ABS

ABS is the most common FDM 3D printing filament for engineering and other professional applications. It produces parts that are strong and impact-resistant. With an HDT of 90 ºC at 0.45MPa, it has better heat resistance than other common filament types like PLA or PETG. ABS parts are ideal for rapid prototyping applications and in education; the low cost and accessible workflow make it a popular choice for quick prints.

Polycarbonate (PC)

Polycarbonate materials, though known for their high tensile strength and temperature resistance, are typically difficult to 3D print because they expand when exposed to heat, and 3D printed parts can crack or malfunction. FDM 3D printer manufacturers often get around this by creating polycarbonate composites with additives that increase their adhesive ability. Some heat-resistant polycarbonate composite filaments can achieve HDTs of up to 110 ºC to 140 ºC at 0.45MPa, but require high temperatures for the print bed and extrusion nozzle, which can limit the types of printers available. 

PEEK

PEEK or PEEK composite filaments offer the highest heat resistance for FDM 3D printing. These filaments, when combined with a material such as carbon fiber, as is the case with PEEK-CF, a carbon fiber PEEK composite, can reach up to 260 ºC before deforming under strain, making them ideal for quick prototyping of electrical connectors, outdoor products, or jigs and fixtures around molding applications and processes. The material is highly chemical resistant, friction resistant, and can be machined once in a solid form post-printing. PEEK’s heat resistant properties make it difficult to melt and extrude smoothly, and many users report that reliability and consistency with PEEK are harder to achieve. PEEK filaments are only compatible with a a few indsutrial FDM printers. To ensure good results, printers must have an extruder that can reach 400 °C, a chamber that can be heated to 120 °C, and a build plate that can heat to 230 °C. PEEK is also subsitantially more expensive than other filaments. 

ULTEM (PEI)

ULTEM is another name for polyetherimide (PEI), a high-performance thermoplastic frequently used in FDM 3D printing because of its heat resistance and strength. With an HDT of around 150 °C at 0.45MPa and a high tensile strength, it is a worthy, and less expensive, replacement for PEEK in a variety of applications. ULTEM is more easily printed than PEEK, but still requires a high heat extruder — around 360 °C — to achieve good results, therefore only a limited range of FDM printers are suited for printing ULTEM filament.

SLA 3D printing delivers smooth, end-use quality parts that can perform in a variety of different environments. Formlabs has developed several high-temperature resistant resins specifically for customers working in extreme environments, in addition to creating several exceptionally strong resins that are also heat-resistant. 

When choosing a resin printer for a heat-resistant 3D printing workflow, it’s important to delineate which mechanical properties are important in addition to HDT. For instance, if your parts will have an end-use operating environment of 200 ºC, that’s the first mechanical property to evaluate. If they only have an end-use operating environment of 150 ºC, you will have more options to choose from, and can then evaluate the printer based on other materials available, surface finish, ease of use, and price.

Clear Resin

Resin 3D printing offers the unique possibility to create truly transparent 3D printed parts. A standard material designed for strength and durability, Clear Resin has good enough heat-resistance that it can be used for higher heat applications such as hot air or gas ducting. With an HDT of 73 °C at 0.45 MPa, this general purpose material is excellent for functional prototyping. Clear Resin can be used for lower temperature molding applications, such as polyurethane molding, as mold temperatures tend to only reach about 60 °C.

Tough Resin

For prototyping strong, stiff, and sturdy parts that should not bend easily, Tough Resin is an excellent choice. It can be used for jigs and fixtures requiring minimal deflection, due to its close simulation of the strength and stiffness of ABS.

High Temp Resin 

For high-temperature applications requiring the smooth surface finish and optimized material properties of SLA resins, High Temp Resin is a great fit. It is a purpose-built resin designed for high-heat resistance. With an HDT of 238 °C at 0.45 MPa, the highest among Formlabs resins, High Temp Resin is ideal for applications like functional prototyping of high-heat consumer electronics, hot air, gas, and fluid flow, and molds and inserts.  

Flame Retardant Resin 

Specially-designed to be self-extinguishing and halogen-free, Flame Retardant Resin is an SLA material with a UL 94 V-0 certification and favorable flame, smoke, and toxicity (FST) ratings. It is ideal for printing flame retardant, heat resistant, stiff, and creep-resistant parts that will perform well long-term in indoor and industrial environments with high temperatures or ignition sources. It has an HDT of 111 ºC at 0.45 MPa.

Rigid 10K Resin 

Rigid 10K Resin is highly glass-filled material that is strong, stiff, and resistant to deformation under a variety of forces, pressures, and torques. It offers a very high heat resistance with an HDT of 238 °C at 0.45 MPa. It is ideal for short-run injection mold masters and inserts, aerodynamic test models, and fluid-exposed jigs, fixtures, and connectors.

Silicone 40A Resin

Combining the high performance of silicone and the design freedom of 3D printing to create highly functional silicone parts with excellent chemical and heat resistance (up to 125 °C), Silicone 40A Resin is the first accessible 100% silicone 3D printing resin. It can achieve fine features as small as 0.3 mm, and complex geometries that are not possible with traditional methods.

Alumina 4N Resin

The only accessible, high-performance technical ceramic, Alumina 4N Resin enables new 3D printing applications for extreme environments. Though printing with it does require extra equipment for a true ceramic burnout, once fully completed, Alumina 4N Resin parts have a maximum working temperature of °C. Using this material opens up new applications in industrial casting, molding, and even in specialty applications such as nuclear waste and liquid metals handling.

The most common material for selective laser sintering is nylon, a highly capable engineering thermoplastic that is resistant to UV, light, heat, moisture, solvents, temperature, and water. It is ideal for complex assemblies and durable parts with high environmental stability. It is available in multiple variants and in composite forms, each tailored to different applications. Other popular SLS materials include the ductile polypropylene (PP) and the flexible TPU, both offering good heat-resistant properties.

Nylon 12 Powder

Balancing strength and detail, Nylon 12 Powder is a highly capable material for both functional prototyping and end-use production of complex assemblies and durable parts with high environmental stability. It offers an HDT of 171 °C at 0.45 MPa, making it one of the best general purpose materials for high-temperature applications.

Nylon 12 GF Powder

Nylon 12 GF Powder is a glass-filled material with enhanced stiffness and heat resistance under strain to endure demanding manufacturing conditions. Ideal for applications where structural rigidity and thermal stability are critical, such as high-performance functional prototypes or robust end-use parts that need to maintain dimensional accuracy.

Nylon 11 Powder

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Nylon 11 Powder is a ductile and robust material with an HDT of 182 °C at 0.45 MPa. It is suitable for 3D printing heat-resistant parts that need to bend or take impact, for functional prototyping and small batch production.

Nylon 11 CF Powder

Nylon 11 CF Powder is a carbon fiber reinforced powder that is ideal for stiff, strong, lightweight parts that can endure high heat for long-term use. It has an HDT of 188 °C at 0.45 MPa, making it Formlabs' most temperature resistant SLS powder. It is ideal for high-heat applications that require strength and stiffness, such as replacement and spare alternatives to metal parts.

Polypropylene Powder

Polypropylene Powder is a genuine polypropylene (PP) that offers high ductility, allowing for repeated bending and flexing while ensuring durability, without the need for inert atmospheric control. With an HDT of 113 °C at 0.45 MPa, it has a bit lower heat resistance than nylon, but can still produce works-like prototypes and durable end-use parts that are chemically resistant, weldable, and watertight.

TPU 90A Powder

SLS 3D printers can also create flexible TPU parts with unmatched design freedom and ease. Combining the temperature resistance, high tear strength, and elongation at break of rubber materials with the versatility of SLS 3D printing, TPU 90A Powder is ideal for producing flexible, skin-safe prototypes and end-use parts that withstand the demands of everyday use.

In modern construction, the ability of materials to endure high temperatures is more than a desired feature; it is a necessity. The selection of materials capable of withstanding prolonged exposure to elevated temperatures is pivotal for ensuring the safety, durability, and functionality of structures. From daily solar heating to exceptional circumstances such as fires, building materials must maintain their integrity to fulfill the principle that failure isn’t an option.

Service temperature is defined as the temperature range in which a material retains its desired mechanical properties. Understanding this concept is crucial in recognizing how various materials respond to prolonged high temperatures. The American Society of Heating, Refrigerating, and Air Conditioning Engineers (ASHRAE) emphasizes the importance of service temperature in their ASHRAE Handbook – Fundamentals, establishing guidelines to assess materials’ thermal properties in construction.¹

This article aims to explore the significance of service temperature in the context of construction materials, with a particular focus on their ability to withstand sustained high temperatures without losing structural integrity. By examining current research, case studies, innovations, and regulations, this article provides a comprehensive overview essential for professionals in the construction industry. Within this context, the idea that failure isn’t an option becomes a guiding principle.

Service Temperature: An Overview

Factors Influencing Service Temperature

Service temperature refers to the temperature range at which a material maintains its mechanical properties without significant alteration. Factors influencing this range include material composite, crystalline structure, impurity levels, and manufacturing processes. Understanding these factors is essential for predicting how a material will behave under specific temperature conditions.

1. Material Composition: The chemical elements and compounds present in the material, along with their ratios, directly influence the material’s response to temperature. Specific alloys or composite materials may have enhanced thermal stability.
2. Crystalline Structure: The arrangement of atoms or molecules within a solid material affects its thermal properties. Crystalline materials might exhibit different temperature behavior compared to amorphous ones, depending on the crystal lattice structure.
3. Impurity Levels: Impurities, or unintended substances within the material, can modify thermal properties by disrupting the regular structure. Evan trace amounts can have significant effects on service temperature.
4. Manufacturing Processes: The methods used to fabricate or process the material, such as forging, casting, or sintering, can induce changes in the microstructure, affecting its thermal behavior.

A comprehensive understanding of these factors enables engineers and scientists to predict how a material will perform under specific temperature conditions, facilitating proper selection for various industrial and construction applications. This understand also contributes to the development of materials with tailored thermal properties to meet unique performance requirements.

Standards and Methods of Measurement

The accurate determination of service temperature requires adherence to standards and testing methodologies. These practices ensure that materials are carefully evaluated for their ability to maintain mechanical properties within specific temperature ranges.

1. General Approaches: Various methods are utilized to measure service temperature, including tension tests, compression tests, and thermal analysis techniques. The selection of the appropriate method depends on the material and its intended application.
2. Metallic Materials Considerations: For metallic materials, specialized test methods, such as ASTM E21 – Standard Test Methods for Elevated Temperature Tension Tests of Metallic Materials, address the unique characteristics of metals at elevated temperatures. These methods guide the industry in evaluating how metals behave under specific thermal conditions.²
3. Application Across Materials: The principles of service temperature measurement apply broadly across different material types, each with specialized standards and test methods tailored to the material’s properties.
4. Importance in Construction: Accurate measurement of service temperature is vital in determining the suitability of materials for applications where high-temperature endurance is necessary, especially in construction where failure isn’t an option.

The Interplay with Building Design

Understanding service temperature is not just about material selection but also plays a significant role in overall building design. Considerations must include the geographical location, the building’s intended use, local climate conditions, and compliance with building codes and regulations.

Service temperature is a nuanced and critical concept in material science and construction. It necessitates rigorous testing standards to ensure materials are suitable for their intended applications, particularly when failure is not an option.

Building Materials’ High-Temperature Performance

Common Materials and Their Temperature Tolerances

Understanding the temperature tolerance of various building materials is fundamental in ensuring their performance under elevated temperatures.

1. Metals: Metals such as steel, aluminum, and copper each have distinct temperature tolerances, which determine their suitability for various applications.
2. Composites and Polymers: These materials often have lower temperature tolerances than metals but can be engineered to meet specific requirements.
3. Insulation Materials: Various insulation materials have unique temperature tolerances, which are critical for their effective performance.³

Effects of Prolonged High-Temperature Exposure

The prolonged exposure of materials to high temperatures can lead to various detrimental effects:

1. Thermal Fatigue: Repeated temperature cycling can cause materials to weaken over time.
2. Thermal Expansion and Contraction: Different materials expand and contract at different rates, which can lead to stresses and potential failure.
3. Degradation: Prolonged high temperatures can cause some materials to degrade, lose strength, or become more brittle.
4. Energy Consumption: Understanding the thermal behavior of materials is essential for energy management in buildings.⁴

Successful Implementations of High-Temperature Resistant Materials

Contrastingly, the proper selection and implementation of materials that resist high temperatures have led to remarkable successes across various industries.

Thermal Efficiency in Industry:

Industrial applications that require building materials to function in extreme temperatures have seen success with specifically engineered materials.

• • GreenGirt CMH™ Z-girts in Building Envelope Design – Incorporating GreenGirt CMH (composite metal hybrid) Z-girts in the building envelope continuous insulation or building envelope design promotes increased thermal efficiency in commercial structures. Within a building envelope, the temperature can be significantly higher than the outside environment, especially in areas exposed to direct sunlight and highly conductive cladding material (such as metal panels) is utilized. Heat transfer involves several mechanisms, including conduction, convection, and radiation. CMH sub-framing contributes to retaining structural integrity in high temperatures while also providing a barrier and eliminating thermal bridging.
  • Nickel-Aluminide Coatings in Industrial Furnace Components – By employing nickel-aluminide coatings in the components of industrial furnaces, manufacturers have successfully resisted high-temperature wear and corrosion. This application extends the lifespan of the equipment, reducing downtime and maintenance costs.

Innovative Engineering Solutions:

Successful examples of innovative solutions using high temperature-resistant materials can be found in various sections, including aerospace and automotive industries.

• • Automotive Industry – Hybrid Metal-Composite in Brake Systems – The hybrid materials ability to combine the strength and heat conductivity of metals with the light weight properties of composite enables superior temperature resilience and weight reduction in brake discs and other brake system components. By optimizing heat dissipation and maintaining performance under intense thermal conditions, the hybrid material contributes to enhanced safety, efficiency, and overall vehicle performance.
  • Aerospace Industry – Nickel-Based Superalloys in Jet Engines – These superalloys can withstand extreme temperatures and stresses without losing mechanical properties, making them indispensable in turbine blades and other critical engine parts. Their use has allowed for more efficient and reliable engine performance, contributing to advances in aircraft technology.

Innovations in Materials and Technologies

The importance of heat-resistant composites and alloys has grown substantially in various industries. These materials offer critical benefits in environments where high temperatures are common, maintaining their properties and integrity.

Composites:

• • Fiber-Reinforced Polymers (FRPs): FRPs are primarily recognized for their lightweight and strength-to-weight ratio. While they have been used in various applications, it’s worth noting that traditional FRPs are generally not designed for high-service temperature environments. Research is ongoing to explore specific fiber and resin combinations that might enhance thermal stability. However, their current utilization in high-temperature scenarios is limited, and careful consideration of their temperature tolerances is essential when selecting them for particular applications. ⁵
  • Ceramic Matrix Composites (CMCs): CMCs are engineered composites that consist of ceramic fibers embedded in a ceramic matrix. Unlike conventional ceramics, these composites offer enhanced toughness, fracture resistance, and flexibility. Most notably, CMCs are renowned for their ability to withstand extremely high temperatures without substantial degradation in structural integrity.
  • Composite Metal Hybrid (CMH): CMH combines the advantages of metals and composites, offering improved heat resistance and structural integrity. These hybrids work well in diverse applications that require both strength and temperature resilience, where failure isn’t an option.

Alloys:

• • Nickel-Based Alloys: Known for their high-temperature stability, these alloys are utilized in demanding applications.
  • Cobalt and Titanium Alloys: These materials offer a balance between strength and temperature resistance, suitable for various high-temperature applications.

Regulatory Framework and Building Codes

Existing Regulations on High-Temperature Resilience

Regulators widely recognize the importance of building materials’ ability to withstand high temperatures. Existing building codes and standards dictate specific requirements for materials to ensure safety, durability, and performance under extreme temperature conditions.

1. International Building Code (IBC): These widely adopted codes provide comprehensive guidance on materials and their appropriate use, including provision for high-temperature resilience.
2. Local Regulations: Different jurisdictions may have additional or unique requirements reflecting local climate and environmental factors.
3. Energy Efficiency Considerations: Regulations that focus on energy efficiency often encompass aspects of thermal performance, thereby influencing material selection and design.

Prospects for Regulatory Changes

The regulatory framework governing the service temperature of building materials is continuously evolving, reflecting technological advances, scientific understanding, and societal needs. High-temperature resilience is becoming an area of increased focus. The following aspects illustrate potential future changes:

1. Integration of new Materials: The development of materials like GreenGirt CMH and other advanced composites with specialized service temperature ranges requires regulations to adapt. This adaptation ensures that we consider the specific properties of these materials, including their behavior at various temperature extremes.
2. Sustainability and Climate Change Considerations: With a growing emphasis on sustainability and climate change adoption, regulatory requirements may shift to include broader considerations of temperature effects. These changes might include specific guidelines on service temperature to ensure long-term performance and resilience in changing environmental conditions.
3. Standards for High-Temperature Performance: As our understanding of materials’ behavior at high temperatures grows, future regulations may incorporate more precise standards for service temperature. These standards could encompass not only resistance to extreme temperatures but also the effects of prolonged exposure to temperatures within and outside a material’s optimal service range.
4. Harmonization with International Guidelines: Global trends in material science and building technology might drive regulatory convergence. This alignment may include shared standards for service temperature, ensuring that materials used in construction meet consistent, internationally recognized criteria for temperature resilience.

This future direction in regulation reflects a complex interplay between technological innovation, environmental stewardship, and the need to ensure that building materials suit a wide range of temperature conditions. By staying abreast of these trends, industry professionals can anticipate and contribute to the evolving regulatory landscape, promoting compliance and innovation in service temperature resilience.

Conclusion

In conclusion, high-temperature endurance is a critical factor to consider when selecting building materials for structures exposure to elevated temperatures. Understanding the factors influencing service temperature, the performance of common materials under high temperatures, and the potential failures and successes is essential for designing resilient and durable structures.

Continuous research and innovation in heat-resistant materials and technologies are necessary to improve the performance and longevity of building materials under high-temperature conditions. Staying updated with the latest advancements and regulatory changes is crucial. This practice ensures the safety and resilience of structures in the face of heat-related challenges.

There are several key recommendations and future considerations to address the challenges and opportunities related to high-temperature endurance in building materials, including:

1. Staying up to date with the latest building codes and regulations is essential. Regularly reviewing and revising existing regulations will ensure they address emerging challenges and incorporate new technologies and materials. Additionally, implementing rigorous testing and certification processes will guarantee that building materials meet the required standards for high-temperature endurance.
2. Education and training programs should target architects, engineers, and construction professionals to enhance their understanding of high-temperature endurance. These programs should also focus on the selection of appropriate materials. Improving knowledge in this area will lead to better decision-making during the design and construction phases.
3. Promoting the use of sustainable and environmentally-friendly high temperature-resistant materials is another important recommendation. Encourage the development and adoption of such materials to reduce environmental impact and enhance energy efficiency.
4. Incorporating resilient design principles is essential. Design structures to withstand and recover from high-temperature events. Consider factors such as compartmentalization, redundancy, and passive fire protection measures. Additionally, evaluate how these elements work together to enhance overall building safety.

If you are interested in learning more about GreenGirt CMH continuous insulation or SMARTci building enclosure systems, please visit our website or contact us today!

© Advanced Architectural Products

Sources:

¹ ASHRAE Handbook—Fundamentals (American Society of Heating, Refrigerating, and Air-Conditioning Engineers)

² ASTM E21-20 – Standard Test Methods for Elevated Temperature Tension Tests of Metallic Materials – https://www.astm.org/standards/e21

³ Touloukian, Y.S., et al., “Thermophysical Properties of Matter,” IFI/Plenum, .

⁴ Turner, W.C., et al., “Energy Management Handbook,” 8th Edition, Fairmont Press, .

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