Impact Resistant FDM Materials

We all know that FDM technology can make pretty tough parts, with genuine engineering-grade polymers like ABS, polycarbonate, and even Ultem (PEI) plastics.  Building these materials within a precisely heated chamber, a la Stratasys, with servo-controlled extrusion ensures that even z-strength, which is the weakest direction of FDM printing, is as high as possible.  Just how strong are these parts?  We put a couple of exotic materials to the test to find out!

PC

First up: one of the most impact resistant polymers: polycarbonate (often abbreviated PC).  In addition to its high impact strength, PC is also stiffer than materials like ABS, and offers far better temperature resistance, too.  

Ultem 9085

Ultem 9085 is among the most special materials that we offer at POP on our FDM machines.  It is generally a stiff and tough thermoplastic but shines due to its amazingly high heat deflection temperature (almost 200C) and its V-0 flammability rating.  As you can see below, it can really take a beating.

Interesting to note: when it did finally break, it didn't do so cleanly across a layer line as you would expect from most FDM machines.  Instead, it produced a ragged edge that spanned 2-3 layers, indicating that print layers were fully fused to each other during printing.  This is in large part due to the heated chambers that we build parts inside of (Stratasys machines).  Ultem, for example, is printed in a chamber that's precisely held at 195C.