Polycarbonate 3D Printing
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About Polycarbonate 3D Printing
Polycarbonate (PC) is a kind of engineering plastic with high strength, high impact resistance and excellent high temperature resistance, and its insulation performance is good, which can be used as electronic and electrical parts. Its glass transition temperature is up to 150°C or more, and the printing difficulty is higher than that of PLA and ABS, requiring higher printing temperatures. Some grades of PC can withstand high temperature autoclave and are ideal for medical and food applications. PC can be rapidly formed by 3D printing for functional prototyping and small volume production in automotive, medical and other industries.
3D Printed Polycarbonate at a Glance
| Application | Manufacturing tools and jigs, functional prototypes |
| Advantages | High temperature resistance, electrically insulating, high tensile strength |
| High impact resistance | Prone to moisture absorption; can warp during printing |
| Disadvantages | Highly susceptible to scratching, hygroscopic |
| Lead Time | 1 day |
| Price | $ |
| Minimum Feature Size | 0.010" (0.254 mm) for parts below 16" (406.4 mm) and 0.013" (0.330 mm) for parts above 16" (406.4 mm) |
| Tolerances | Z plane: +/- 0.010” (0.254 mm) for the first inch, plus +/- 0.002” (0.0508 mm) for every inch thereafter. XY plane: +/- 0.004” (0.1016 mm) for the first inch, plus +/- 0.002” (0.0508 mm) for every inch thereafter. |
| Layer Height | 0.010" (0.254 mm) for parts below 16" (406.4 mm) and 0.013" (0.330 mm) for parts above 16" (406.4 mm) |
| Max Part Size | 24” x 36” x 36” (610 mm x 915 mm x 915 mm) |
FDM PC
Standard polycarbonate material mechanical strength is outstanding, including tensile strength, impact strength and bending strength are better than other engineering plastics such as ABS, but also has high hardness and thermal stability. This makes standard PCS ideal for functional prototyping and tooling, as well as structural end-use parts that require high rigidity and impact resistance, replacing metal for a wide range of high-strength components.
FDM PC Properties
| Tensile Strength (MPa) | Elongation at Break (%) | Hardness (Rockwell) | Heat Deflection Temperature (℃) | Glass Transition (℃) |
|---|---|---|---|---|
| 68 | 5 | 115 | 138 | 161 |
FDM PC-ABS
PC-ABS is a transitional engineering plastic that combines the high strength and high temperature resistance of polycarbonate with the toughness and processability of ABS. It inherits the common advantages of the two materials, with a certain strength, toughness, processability and high temperature resistance, and can be produced through 3D printing technology that requires both a certain strength and a certain toughness and processability of various types of engineering parts and product prototypes, with a wide range of applications.
FDM PC-ABS Properties
| Tensile Strength (MPa) | Elongation at Break (%) | Hardness (Rockwell) | Heat Deflection Temperature (°C) | Glass Transition (°C) |
|---|---|---|---|---|
| 29 | 2 | 110 | 110 | 125 |
FDM PC-ISO
This special grade of polycarbonate material is both biocompatible and repeatable, non-toxic and harmless, and meets ISO 10993 and USP IV standards. It inherits the excellent mechanical strength and high temperature resistance of polycarbonate itself, and can be autoclaved with gamma rays or ETO gas without residual contamination. Therefore, this PC material is an ideal 3D printing material choice for the medical and food industries.
FDM PC-ISO Properties
| Tensile Strength (MPa) | Elongation at Break (%) | Flexural Strength (MPa) | Heat Deflection Temperature (°C) | Impact Strength Notched (J/m) |
|---|---|---|---|---|
| 57 | 4 | 90 | 133 | 86 |
Finishes
When using FDM technology to print polycarbonate, the post processing mainly by removing the support structure, grinding treatment to achieve the basic effect. Its surface will have an obvious layered texture, which cannot achieve a high degree of smoothness. With three color options of black, white and transparent, richer color personalization is not possible. If you want a highly smooth look, consider using technologies such as SLS or MJF. It can also be painted and sprayed to achieve personalized customization of the appearance. The polycarbonate material itself can be finely matted, which can significantly improve the surface texture and achieve a better smoothness.
Cost-saving Design Tips
When printing polycarbonate using FDM technology, you need to pay attention to the following design strategies:
- The printing direction makes the overhanging part need to be supported, and large inner cavity structure should be avoided. Soluble support materials can be used for removal.
- In order to exert the mechanical properties of the material, avoid designing the structure that bears the load in the vertical printing direction.
- PC is relatively expensive and is recommended only when high strength and high heat resistance conditions are required.
- Evaluate the need for a PC based on the actual load conditions and operating environment.