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, often enhanced with flame retardant additives, 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.aFlame-retardant

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.

Introduction to Flame Retardant Polymers

Flame retardant polymers are a specialized class of materials engineered to resist ignition and slow fire spread. These fire-resistant materials are indispensable in industries where safety is paramount, such as construction, automotive, and electronics. Flame retardant polymers can be derived from various base materials, including plastics, elastomers, and composites. These polymers are often treated with specific additives to enhance their fire-resistant properties. These additives can include halogenated flame retardants, brominated flame retardants, and inorganic flame retardants, each contributing to the material’s overall flame retardancy. By incorporating these additives, flame retardant polymers become more effective in preventing fires and ensuring safety in critical applications.

Properties of Flame Retardant Polymer Materials

Flame-retardant polymer materials possess several key properties that make them essential for fire safety applications:

• High Heat Resistance: These materials can withstand elevated temperatures without igniting or melting, making them suitable for environments where high heat is a concern.

• Low Flammability: Designed to resist ignition, flame retardant polymers slow the spread of fire, providing valuable time for evacuation and firefighting efforts.

• High Wear Resistance: Besides their fire-resistant properties, these polymers are durable and can withstand significant wear and tear, making them ideal for use in construction and automotive applications.

• Good Chemical Resistance: Flame retardant polymers resist various chemicals, allowing them to maintain their integrity and performance even in harsh environments.

These properties collectively enhance the safety and reliability of flame-retardant polymer materials in various applications, ensuring they meet stringent fire safety standards.

Flame Retardant Polymer Materials Applications

Aerospace

Safety is critical in the aerospace industry, where flame-retardant plastics are essential. Strict regulations set the standard, so the industry must follow them 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. Halogen flame retardants are commonly used in the rail industry to meet these stringent safety standards. 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. Metal oxides are frequently used in these components to enhance their flame-retardant properties. 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.

Construction Engineering

In construction engineering, flame retardant polymers play a crucial role in enhancing fire safety. These materials are used in several key applications:

• Building Insulation: Flame retardant polymers are employed to insulate buildings, reducing the risk of fire and improving energy efficiency.

• Roofing Materials: These polymers are used in roofing materials to enhance fire resistance and durability, providing an added layer of protection against potential fire hazards.

• Wall Materials: Flame-retardant polymers are incorporated into wall materials to prevent the spread of fire and improve the overall safety and longevity of buildings.

By integrating flame-retardant polymers into construction materials, engineers can significantly reduce the risk of fire and enhance the safety of structures.

Other Applications

Beyond construction, flame-retardant polymers are utilized in various other industries:

• Automotive: In the automotive sector, flame-retardant polymers are used in components such as seat belts and airbags, where fire resistance is critical for passenger safety.

• Electronics: These polymers are essential in electronic applications, including circuit boards and wiring, where they help prevent electrical fires and ensure the safe operation of devices.

• Aerospace: In the aerospace industry, flame retardant polymers are used in aircraft and spacecraft components, providing vital fire resistance in high-risk environments.

The versatility and effectiveness of flame retardant polymers make them indispensable across multiple sectors, enhancing safety and reliability.

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

The terms flame-resistant and flame-retardant often need clarification. Flame-retardant materials are designed to prevent fire spread on combustible materials, while flame-resistant materials are built to avoid burning altogether. 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.

Standards and Classifications for Flame Retardant Polymers

To ensure the safety and effectiveness of flame retardant polymers, several standards and classifications are in place:

• UL94: This internationally recognized flammability test for plastics evaluates the material’s ability to extinguish a flame after ignition.

• EN-45545: A European standard for fire protection on railway vehicles, EN-45545 classifies materials based on their fire behaviour and smoke emissions.

• FMVSS 302: This automotive standard requires materials to meet specific flammability requirements, ensuring the safety of vehicle components.

• FAR 25.853: An aviation standard, FAR 25.853, mandates that materials used in aircraft meet stringent flammability requirements to ensure passenger safety.

These standards and classifications provide a comprehensive framework for assessing the fire-resistant properties of flame retardant polymers, ensuring they meet the necessary safety requirements for their intended applications.

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).