Smart Molding International 2-2025

39 www.smart-molding.com additive manufacturing contain many crystals (grains) that differ in orientation. Since thermoplastic polymer chains are chemically separate, the attraction force is weaker than the metallic bonding between crystals in metals. As a result, metals are more resistant to elastic deformation (stiffer) and generallymore temperature resistant. It’s the reason why metals have been the default choice for mechanical and thermal applications. But as we engineer more advanced thermoplastics, the effective strength begins to match and, in some cases, surpass metals. Two Suitable Metal Replacement Materials: PEEK and ULTEM™ PEEK and ULTEM™ 9085 are two of the most popular polymers that have been considered for replacing metals. The specific graph compares these materials to Aluminum 6061, an alloy used in the construction of aircraft structures, automotive parts, marine structures, and consumer products. CF PEEK contains 10% carbon fiber which increases the strength and stiffness of baseline PEEK. These are several industries where metal replacement can provide significant weight savings while maintaining the required mechanical and thermal properties. In addition, these high temperature thermoplastics demonstrate superior chemical and corrosion resistance compared to common in-service metals. We can see that PEEK and ULTEM™ o ffe rs between 50 - 60% we i ght reduction, while maintaining high strength and high heat resistance. Replacing metals means greater fuel savings, lower carbon emissions or increased payload capabilities for the transportation industry. In addition, these materials possess high chemical resistance, high impact resistance, are UL94-V0 flammability rated, and meets FAR 25.853 flame, smoke, and toxicity (FST) requirements, a requirement in aerospace and naval applications. How to 3D Print PEEK and ULTEM™ Simply 3D printing high performance materials won’t guarantee that the parts will possess the reported mechanical, thermal, and chemical properties. To match these properties, the selected 3D printer needs a precision-controlled high temperature build chamber (up to 260°C), 500°C extruders, and configurable print surfaces. Printing at temperatures colder than 140°C can significantly reduce part strength, chemical resistance, and require further annealing in which warping is unavoidable. AON3D Hylo is a large, high temperature industrial 3D printer optimized to make 3D printing high performance materials like PEEK and ULTEM™ 9085 easy and accessible. About AON3D Founded in 2015, AON3D is a venture capital-backed, Montreal-based additive manufacturing hardware, software, and material company. Its solutions drive innovation for hundreds of businesses in 25+ countries worldwide, ranging from small businesses to multinational Fortune 500 corporations. AON3D www.aon3d.com Specific strength is used to evaluate the tensile strength of a material compared to its density: The higher specific strength of thermoplastics allows for lighter weight parts while maintaining the same strength properties of metals The continuous use temperature is based on the allowable operating temperature for each material based on given industry standards and manufacturers technical datasheets (all pictures: AON3D) An aerospace bracket, printed in Polyimide (TPI), withstands a 432 kg load before fracturing across several layers, exhibiting better interlayer weld strength and isotropy compared to ULTEM 9085