ULTEM & PEEK: Mastering High‑Performance 3D Printing Materials

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High‑performance thermoplastics, such as PEI, PAEK and PPSU, are increasingly in demand for industrial‑grade manufacturing applications.

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Within the field of additive manufacturing, Fused Deposition Modelling (FDM) is the most common technology for printing with these filaments.

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In this tutorial, we explore 3D printing with high‑performance thermoplastics, covering pros, cons, applications, and key printing requirements.

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Why Use High‑Performance Thermoplastics?

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Unlike PLA or ABS, high‑performance thermoplastics offer superior mechanical properties—strength, durability, heat and chemical resistance—making them ideal for engineering applications.

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The Materials

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PEI (ULTEM)

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Polyetherimide (PEI), known commercially as ULTEM, is a high‑performance engineering thermoplastic available in amber or transparent colors. ULTEM 9085 and ULTEM 1010 are the most widely used grades; Sabic has recently introduced two new ULTEM‑1010‑based variants.

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ULTEM 9085: Key Benefits

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• Inherently flame‑retardant (FST‑compliant, certified for aircraft components)
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• High strength‑to‑weight ratio—lighter than aluminum yet comparable impact strength
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• Heat deflection temperature of 167 °C
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• Excellent chemical resistance to automotive fluids, aqueous solutions, and alcohols
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Applications

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Ideal for aerospace and automotive parts: interior components, ductwork, electrical enclosures, and customized tools. Latécoère uses ULTEM 9085 to create 50 % lighter aircraft tooling.

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Recommended printer settings

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• Extruder temperature: 350 – 380 °C (all‑metal extruder)
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• Print bed temperature: 140 – 160 °C
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• Bed cover: Kapton tape, lightly sanded FR4, or perf board
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• Heated enclosure: required (warm to hot build environment)
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• Printing speed: 20 – 30 mm/s
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ULTEM 1010: Key Benefits

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• Highest tensile strength among FDM filaments
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• Excellent thermal stability—tolerates steam sterilization
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• Biocompatible (ISO 10993/USP Class VI)
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• NSF 51 food‑contact certification
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Applications

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Used in out‑of‑cabin aerospace components, automotive parts, food‑production tools, and custom medical devices such as surgical guides and trays.

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Recommended printer settings

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• Extruder temperature: 370 – 390 °C (all‑metal extruder)
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• Print bed temperature: 120 – 160 °C
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• Bed cover: Kapton tape, lightly sanded FR4, or perf board
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• Heated enclosure: required
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• Printing speed: 20 – 30 mm/s
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PAEK Family (PEEK & PEKK)

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Polyaryletherketone (PAEK) includes PEEK and PEKK—both high‑temperature, high‑strength thermoplastics.

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PEEK: Key Benefits

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• Heat resistance up to 260 °C
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• Excellent strength‑to‑weight ratio and abrasion resistance
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• Strong chemical resistance to solvents, acids, and bases
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• Compatible with autoclave sterilization
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Applications

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Airbus Helicopters replaced aluminum door fittings on the A350 XWB with PEEK, cutting weight by 40 % and improving functionality. PEEK also suits automotive bearings, piston parts, and custom prosthetics.

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Recommended printer settings

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• Extruder temperature: 360 – 450 °C (all‑metal extruder)
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• Print bed temperature: ≥120 °C
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• Bed cover: Kapton tape
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• Heated enclosure: 70 – 150 °C
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• Printing speed: 10 – 50 mm/s (0.2 mm layer)
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PEKK: Key Benefits

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• High strength, toughness, and wear resistance
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• Superior heat and chemical resistance
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Applications

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Suitable for components exposed to jet fuel, oil, and hydraulics; used in spacecraft parts with low outgassing. Boeing’s Starliner incorporates over 500 PEKK parts, offering ~60 % cost savings.

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Recommended printer settings

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• Extruder temperature: 345 – 375 °C (all‑metal extruder)
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• Print bed temperature: 120 – 140 °C
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• Bed cover: Kapton tape
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• Heated enclosure: 70 – 150 °C
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• Printing speed: 20 – 50 mm/s (0.2 mm layer)
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PPSU (PPSF)

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Polyphenylsulfone (PPSU) ranks among the strongest 3D‑printing thermoplastics for engineering.

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PPSU: Key Benefits

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• Heat deflection temperature of 205 °C and high chemical resistance
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• Strong and durable
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• High resistance to gamma radiation; sterilization‑capable (EtO, steam, plasma, dry heat, cold)
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Applications

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Versatile across automotive, medical, and low‑volume injection molding. Its steam‑sterilization resistance makes it ideal for medical tools; automotive under‑hood parts and electronic enclosures also benefit.

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Recommended printer settings

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• Extruder temperature: 360 – 390 °C (all‑metal extruder)
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• Print bed temperature: 140 – 160 °C
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• Bed cover: Kapton tape
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• Heated enclosure: required
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• Printing speed: 1000 mm/min
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The Limitations of High‑Performance Thermoplastics

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Primary challenges include high material cost and the need for advanced printing expertise. Limited availability of FDM printers capable of handling these temperatures and the requirement for post‑processing (e.g., annealing for PEEK/PEKK) also constrain adoption.

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Conclusion

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High‑performance thermoplastics are rapidly evolving. Their unique properties often provide cost‑effective, lightweight alternatives to metal alloys, opening new opportunities for engineering design. As manufacturers expand the material portfolio, prices are expected to decline, broadening their application scope and strengthening the future of high‑performance 3D printing.

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