Engineering Materials Selection Guide

Why Material Selection Matters

Choosing the right polymer for your application isn't just about getting the part printed - it's about ensuring the part performs under real-world conditions. Heat resistance, chemical compatibility, dimensional stability, and mechanical properties all vary dramatically across materials.

This guide provides engineering-level data to help you select materials based on your application requirements. We cover thermal performance, mechanical properties, chemical resistance, and practical considerations for each material class.

Our Printing Capabilities

We operate multiple FDM printers with varying chamber capabilities:

Standard Chamber (65°C): PA6, PA12, PETG, PET-CF, ASA, ABS-CF/GF, PC
High-Temp Chamber (90-150°C): PPA, PPS (limited), advanced composites
Ultra High-Temp (150°C+): PEKK, PSU, Ultem (contract partners)

For materials requiring chamber temps above our in-house capacity, we work with qualified partners who specialize in ultra-high-performance polymers.

Part 1: High-Performance Polymers

These materials represent the top tier of engineering thermoplastics. Aerospace, medical, automotive, and industrial applications where performance is non-negotiable.

PEKK (Polyetherketoneketone)

Aerospace High-Temp High Strength

PEKK is a high-performance semicrystalline thermoplastic in the PAEK family. It offers exceptional mechanical strength, heat resistance, and chemical resistance, making it suitable for demanding aerospace and industrial applications.

Thermal Properties

Glass Transition (Tg)	162°C
Heat Deflection Temp (HDT @0.45 MPa)	260°C
Continuous Service Temp	250°C
Print Temp	360-400°C
Bed Temp	120-160°C
Chamber Temp (Required)	70-150°C

Mechanical Properties

Tensile Strength	95-110 MPa
Tensile Modulus	3.6-4.0 GPa
Flexural Strength	140-160 MPa
Elongation at Break	3-5%
Impact Strength (Izod)	7-9 kJ/m²

Other Properties

Chemical Resistance	Excellent
UV Resistance	Good
Moisture Absorption	0.1% (24h)
Density	1.3 g/cm³
Flame Rating	V-0

Typical Applications

Aerospace components (cabin interiors, ducting, structural brackets)
Oil & gas downhole tools
Automotive under-hood components
Medical sterilizable parts
High-temperature electrical insulators

Design & Printing Considerations

Warping: Significant - requires heated chamber and careful print orientation
Support Removal: Challenging - material strength makes support removal difficult
Post-Processing: Can be annealed for improved crystallinity and properties
Cost: Very high (~$300-500/kg)
Printing Difficulty: Expert level - requires specialized equipment

Note: PEKK printing requires ultra-high-temp equipment. We work with qualified partners for PEKK production.

PPS (Polyphenylene Sulfide)

Chemical Resistant High-Temp Electrical

PPS is a high-performance semicrystalline thermoplastic known for exceptional chemical resistance and high-temperature stability. Widely used in automotive and electronics applications.

Thermal Properties

Glass Transition (Tg)	85-90°C
Heat Deflection Temp (HDT @1.8 MPa)	220°C
Continuous Service Temp	200-220°C
Print Temp	310-350°C
Bed Temp	80-90°C
Chamber Temp	65-100°C

Mechanical Properties

Tensile Strength	65-85 MPa
Tensile Modulus	3.3-3.8 GPa
Flexural Strength	110-130 MPa
Elongation at Break	1.5-3%
Impact Strength (Izod)	2-3 kJ/m²

Other Properties

Chemical Resistance	Excellent
UV Resistance	Fair
Moisture Absorption	0.02% (24h)
Density	1.35 g/cm³
Dielectric Strength	20 kV/mm

Typical Applications

Automotive fuel system components
Electronics housings and connectors
Chemical processing equipment
High-temperature electrical insulators
Pump and valve components

Design & Printing Considerations

Warping: Moderate - heated bed required, chamber helpful
Brittleness: Relatively brittle - avoid thin walls and sharp corners
Chemical Compatibility: Resistant to most solvents, acids, and bases
Cost: High (~$150-250/kg)
Printing Difficulty: Advanced - requires high-temp capable hotend

PPA (Polyphthalamide - High-Temp Nylon)

Automotive High-Temp Metal Replacement

PPA is a high-performance polyamide with significantly better heat resistance and lower moisture absorption than standard nylons. Often used as a metal replacement in automotive and industrial applications.

Thermal Properties

Glass Transition (Tg)	125-130°C
Heat Deflection Temp (HDT @1.8 MPa)	220°C
Continuous Service Temp	200°C
Print Temp	280-310°C
Bed Temp	60-80°C
Chamber Temp	Optional (improves results)

Mechanical Properties

Tensile Strength	90-120 MPa
Tensile Modulus	2.5-3.5 GPa
Flexural Strength	130-160 MPa
Elongation at Break	3-5%
Impact Strength (Izod)	6-8 kJ/m²

Other Properties

Chemical Resistance	Good
UV Resistance	Fair
Moisture Absorption	0.8% (24h)
Density	1.14 g/cm³
UL94 Rating	V-0 or V-2

Typical Applications

Automotive under-hood components (air intake, cooling)
Metal replacement brackets and structural parts
Industrial tooling and jigs
High-temperature snap-fit assemblies
Fluid handling components

Design & Printing Considerations

Moisture Sensitivity: Lower than PA6/12 but still requires dry storage
Warping: Moderate - heated bed essential, chamber helps
Layer Adhesion: Excellent when printed properly
Cost: Moderate to High (~$80-150/kg)
Printing Difficulty: Intermediate - accessible with proper equipment

We Print This: PPA is within our standard capabilities - good heat resistance without ultra-high-temp requirements.