Explained: 3D Printing with Flame Retardant Polymers

Many 3D printing materials regularly hit the market, but flame-retardant polymers are one growing category. Flame retardant materials prevent the spread of fires and are essential for some use cases. They can withstand high temperatures and are much less likely to catch and stay on fire.

In some regions and industries, laws and regulations require flame-retardant properties of end-use parts. In other cases, 3D-printed tooling must be able to withstand high temperatures. Flame retardant materials help improve safety. Otherwise, there’d be a risk of part failure or spreading fire.

For all these reasons, flame retardant materials meet high certification standards for specific industries. This guide will look at some critical use cases and detail some available flame retardant materials.

Flame Retardant Polymer Applications

Aerospace

Safety is critical in the aerospace industry. Strict regulations set the standard, so the industry needs to follow the rules when deploying parts. Airbus successfully built interior cabin parts, such as panels, with flame-retardant materials using selective laser sintering and fused deposition modeling. Emirates also uses flame-retardant materials to 3D print some parts, such as video monitor covers. All these parts follow strict heat release requirements, making them effective in the case of a fire.

Rail

Like the aerospace industry, the rail industry is also subject to strict safety regulations. 3D printing with flame-retardant materials has proven to be quite helpful. Alstom, the multi-national manufacturer, uses flame-retardant 3D-printed air vents on some trains. Additive manufacturing is especially beneficial for creating spare parts on demand in the rail industry, reducing lead times and storage costs.

Electronics

Flame retardancy is a helpful feature for electronic components. 3D printed materials are commonly used in “passive” parts of the element – such as housings and connectors – in case of an electrical fault. These parts are not only flame retardant but can be highly customized.

Flame Resistant vs. Flame Retardant: What’s the Difference? 

The terms flame-resistant and flame-retardant often need clarification. Understandably so, as there are some similarities between the two terms. The main difference is that flame-retardant materials can resist certain heat levels, but they’re designed to prevent fires from spreading. Flame-resistant materials are built to avoid burning at all.

Flame Retardant Polymer Examples

Many different flame retardant polymers are available, and companies regularly develop new materials or variations. Several different flame-retardant polymers are available on the MakerVerse platform.

PA-12 Flame Retardant

Technology: Selective Laser Sintering (SLS)

PA 12 is a standard material when using SLS  technology. It combines high tensile strength with stability. This variant of the PA 12 version has a unique flame retardant chemical added to it. This material is commonly used in the aerospace and rail sectors. See the datasheet.

Essential Qualifications: CS 25 (European Aviation Safety Agency specification for large airplanes), JAR 25 (Joint Aviation Requirement), FAR 25 (USA Federal Aviation Administration), UL 94 V-0 (Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances).

ULTEM 1010

Technology: Fused Deposition Modeling (FDM)

ULTEM 1010 is a high-performance thermoplastic polyetherimide (PEI) with the lowest coefficient of thermal expansion among all FDM materials. It also boasts high heat resistance, tensile strength, and chemical resistance, making it ideal for challenging and specialized use cases. Please take a look at the data sheet.

Essential Qualifications:  FAR 25 and OSU 65/65 (USA Federal Aviation Administration) UL 94 V-0 and 5 VA

ULTEM 9085

Technology: Fused Deposition Modeling (FDM)

ULTEM 9085 is a high-performance thermoplastic offering high strength. That, combined with its flame retardancy, makes it widely used in the aviation and rail industries. Please take a look at the data sheet.

Essential Qualifications:  FAR 25 and OSU 65/65, EN45545 R6-HL3 rating (European Railway Standard for Fire Safety), UN ECE Regulation 118 (Fire Protection of Buses).