Discover why ULTEM 9085 (Thermax PEI 9085) is one of the most trusted high-performance filaments in aerospace, automotive, and industrial applications.
What is ULTEM 9085?
ULTEM 9085 is the trade name for a high-performance thermoplastic known as PEI (polyetherimide), originally developed by GE Plastics and now manufactured by SABIC. This specific grade is a blend of PEI and polycarbonate, enhancing both processability and impact resistance while maintaining key strengths like flame retardance and dimensional stability.
With a UL94 V-0 flame rating and aerospace-grade certifications, ULTEM 9085 stands out for its mechanical integrity, heat resistance, and low toxicity—making it ideal for demanding environments.
Real-World Applications
This isn’t just lab material—it’s already in the sky and on the ground:
- Airbus: Prints interior cabin parts like ducts and panels for the A350.
- BAE Systems: Replaces metal jigs and fixtures with lightweight ULTEM tools.
- Boom Supersonic: Uses it in flight-grade components for their XB1 jet.
- General Motors & Volkswagen: Employ it under the hood and on the factory floor.
- Ford: Prints HVAC ducting prototypes for real-world vehicle testing.
- Siemens: Uses it for electronics enclosures where flame and insulation matter.
- NASA: Tests it in thermo-vac chambers simulating space environments.
Technical Specs at a Glance
- Tensile Strength: ~54 MPa
- Tensile Modulus: 2200 MPa
- Flexural Strength: 90 MPa
- Glass Transition Temp: 186°C
- Heat Deflection Temp (at 1.8MPa): 158°C
- FST Rating: UL94 V-0
With built-in flame resistance, low smoke emission, great chemical resistance, and excellent electrical insulation, ULTEM 9085 is a powerhouse material ready for mission-critical jobs.
Printing with ULTEM 9085
Despite being a high-performance thermoplastic, ULTEM 9085 is surprisingly easy to print—provided you have the right equipment:
- Extruder Temp: 390°C+
- Heated Bed: 160°C+
- Chamber Temp: 90°C minimum (140°C preferred for large parts)
- Drying Requirement: 4 hours at 120°C
Print quality is impressive—featuring a pearlescent finish, strong inter-layer adhesion, and clean surface quality. Drying the filament is critical to avoid print defects. A filament dryer, like those from Vision Miner, can make a world of difference.
Testing & Performance Results
Stress Testing
Using a Universal Testing Machine (UTM), samples printed along X, Y, and Z axes were tested. As expected, the Z-axis samples broke along layer lines, while XY samples withstood more stress before shearing.
Microscopic Analysis
High-resolution microscopes revealed detailed failure points, allowing insights into internal layer adhesion, infill visibility, and thermal deformation characteristics. The pearlescent surface showed minor discoloration at stress points but maintained structural integrity.
Quick Break & Torque Tests
Manual bend and torque tests demonstrated the ductility and toughness of the material. Even under extreme stress, ULTEM 9085 deformed significantly before failure, showing excellent toughness for 3D-printed parts.
Flame Resistance Test
ULTEM 9085 passed flame testing with flying colors—self-extinguishing within seconds and showing minimal smoke. It retains most of its structure after exposure, making it a prime choice for FST-critical applications like aircraft interiors and electronics.
Cost & Availability
For a high-performance material, ULTEM 9085 is reasonably priced:
- 1kg spool: ~$220
- 500g test spool: ~$145
Available from trusted suppliers like Vision Miner, it’s an excellent entry point for users looking to explore professional-grade thermoplastics.
Recommended Printers & Equipment
To get the best results, use a printer designed for high-temp materials. The Vision Miner 22 IDEX is a solid choice, offering dual extrusion, heated chamber, and built-in profiles for materials like ULTEM 9085.
A proper drying kit is essential—moisture will ruin your prints. Keep your filament dry, and your parts will be strong, consistent, and clean every time.
Final Thoughts
ULTEM 9085 isn’t just hype—it’s one of the most capable materials available for 3D printing today. From aerospace brackets to automotive ducting and custom jigs, its flame resistance, mechanical durability, and printability make it a go-to for professionals.
Curious to see how far this material can go? Tune into future testing where parts are pushed even further under controlled and real-world conditions.
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