Introduction to High-Temp 3D Printing
High-temperature filament 3D printing with engineering-grade materials, such as ULTEM™, PEI, and carbon fiber composites, is an advanced level of 3D printing. Unlike PLA or PETG, high-temp materials require meticulous tuning for successful prints. This guide explores the processes, techniques, and settings that help achieve strong, functional high-temperature parts.
Challenges in High-Temperature Printing
Materials like ULTEM™ and PEEK demand precise control of temperature, drying, and orientation. Without proper handling, prints may warp, delaminate, or fuse incorrectly. These materials are highly sensitive to humidity and nozzle temperature, which means you’ll need a well-dried filament, an ideal temperature profile, and potentially, orientation adjustments to produce high-quality parts.
Key Techniques for High-Temp Tuning
1. Use a Slicer Cut Tool for Test Prints
Instead of printing full models during each tuning iteration, you can use a slicer’s cut tool to focus on specific problem areas. This technique saves time and material by isolating challenging sections, such as overhangs or moving parts, before committing to a full print.
2. Dry Your Filament Thoroughly
Proper drying is essential for achieving quality prints with high-temp materials. Filament that isn’t thoroughly dried will absorb moisture, leading to defects like stringing, burn marks, and blobs. Always use a filament dryer or oven to remove moisture before printing.
3. Optimize Layer Height and Nozzle Temperature
High-temp materials require fine-tuned layer heights and nozzle temperatures. For ULTEM™ 9085, for example, lowering the layer height and adjusting nozzle temps between 370–390°C yields smoother results. Test variations to determine the perfect setting for each material and geometry.
4. Brass vs. Hardened Steel Nozzles
For pristine, defect-free prints, hardened steel nozzles are durable but can impact thermal transfer, often requiring an increase in nozzle temperature. Brass nozzles, however, provide better thermal conductivity for non-abrasive filaments, ensuring consistent heat distribution and better print finishes.
Best Practices for Common High-Temp Materials
ULTEM™ 9085 and ULTEM™ 1010
ULTEM™ requires careful temperature adjustments and orientation considerations. Printing with a chamber temperature around 90°C, bed temperature between 160–180°C, and nozzle around 380°C helps achieve optimal adhesion and minimizes warping. Printing thinner walls improves success rates with large parts, preventing delamination.
Carbon Fiber Peek and Nylon (CFPA6)
Carbon fiber composites, such as CFPA6, benefit from layer thickness adjustments and nozzle size changes. By using a wider nozzle (e.g., 0.6 mm instead of 0.4 mm), print speed improves, and strength increases due to better adhesion. Ensure that the filament is dry, as these materials are sensitive to moisture.
Advanced Tuning Tips
Maintain Minimum Shell Thickness
Setting a minimum shell thickness in your slicer can greatly enhance part durability. Specify values that align with your filament type and print strength requirements, such as 1 mm for nylon or higher for high-strength applications.
Control Volumetric Flow and Speed
Adjusting the volumetric flow settings to around 5–6 mm³/s ensures consistent material flow, especially for high-temp filaments. For optimal results, setting print speeds to 30 mm/s provides a balance between speed and precision, reducing risks of layer skipping or nozzle clogging.
Conclusion
High-temperature 3D printing may seem challenging, but with the right equipment, drying techniques, and tuning, you can achieve industry-level precision and part quality. These steps form a reliable foundation for users exploring the possibilities of high-temp filaments.
Curious about how these settings impact your 3D prints? Experiment with the settings mentioned above, and feel free to reach out if you need advice on printers or materials for your specific applications!