Withstanding the Heat: Advances in High Temperature Resistant 3D Printing

Obtaining heat resistance in printed components is critical for applications like aerospace, automotive, and energy systems. New material options and printing techniques now enable additive manufacturing of parts that retain strength and shape at elevated temperatures exceeding 1000°C.

As 3D printing expands into extreme temperature environments, engineers require materials and processes that can withstand intense heat without losing mechanical performance.

From advanced jet engines to next-generation nuclear reactors, components face temperatures exceeding 1000°C during operation. New developments in high temperature polymers, refractory metals, and process refinements now bring these harsh environments within the capabilities of additive manufacturing.

Key Materials Advances Expanding Heat Resistant 3D Printing

1. Heat Resistant Polymers

While most conventional polymers degrade above 300°C, novel high performance options allow printed plastic components to endure much higher temperatures.

PEEK and PEKK – Exceptional thermoplastics like polyetheretherketone (PEEK) and polyetherketoneketone (PEKK) retain strength and toughness after prolonged exposure above 300°C. This enables aerospace and industrial printed parts resisting typical service temperatures.

High Temperature Resins – Chemically engineered thermoset resins cure into heavily crosslinked polymer networks demonstrating remarkable thermal stability approaching 500°C. Allylic resins and bismaleimides are popular choices.

Liquid Crystal Polymers – Rigid backbone liquid crystal polymers (LCPs) like Zenite® melt at extreme temperatures over 330°C while maintaining tensile strength and chemical resistance up to 250°C.

Ceramic Filled Composites – Adding high temperature stable reinforcements like chopped carbon or silicon carbide fibers/particles to thermoplastic filaments bolsters resulting composite heat resistance.

2. Refractory Metals

Advanced refractory metals and superalloys retain exceptional strength and creep resistance even at extreme temperatures exceeding 1000°C.

Nickel Superalloys – Alloys of nickel with additions of chromium, aluminum, titanium, and other elements display remarkable performance in hot section turbine blades at temperatures often above 1000°C.

Refractory Metals – Inherently heat resistant metals like molybdenum, niobium and tungsten alloys maintain strength at operating temperatures over 2000°C. This enables printed rocket nozzles and nuclear applications.

Metal Matrix Composites – Reinforcing refractory metals like tungsten with dispersed ceramic particulates enhances high temperature creep resistance compared to unreinforced metals.

Additive Manufacturing Process Refinements

Beyond material selection, process innovations during and after 3D printing further maximize resulting heat resistance.

High Temperature Heat Treatments – Post-printing heat exposure just below sintering temperatures drives off impurities while initiating crucial microstructural changes to maximize thermal stability.

Inert Atmosphere Printing – Oxygen-free argon or nitrogen build envelopes prevent oxidative damage during printing at elevated temperatures.

Directed Energy Deposition – Precisely controlling melt pool sizes and rapid solidification rates during DED processes like laser metal deposition results in superior high temperature properties.

With expanding possibilities for additive manufacturing across extreme temperature environments, ongoing material and process innovations promise to enable unprecedented heat resistant printed components. Latest developments now bring over 1000°C stability within reach.