PA-based Material for SLS Industrial Applications: Interview with Forward AM by BASF

TAGS:  3D Printing      Automotive    

With the rise of high-performance needs and design complexity, manufacturers are increasingly relying on additive manufacturing and looking for new materials to meet their industrial application needs. Forward AM offers a wide range of materials for additive manufacturing, from filaments to powders.

Forward AM offers industrial-grade PA-based materials for Powder Bed Fusion suitable for competitive applications. They have developed Ultrasint® PA6 LM powder, for customers who already operate standard LS equipment but want to take advantage of the superior properties of PA6.

Fleurine Eberle, Product Manager for Powder Bed Fusion at Forward AM, shared with SpecialChem more details about Ultrasint® PA6 LM, such as:

• How it is an alternative to commonly used PA12?
• What are the various benefits it offers for additive manufacturing?

Let’s take a look…

#1 In Powder Bed Fusion, PA12 is the most widely used polymer. With Ultrasint® PA6 LM, Forward AM offers an alternative – What is it all about?

FE: That’s correct, PA12 is generally commonly used as a material in Additive Manufacturing. We at Forward AM developed BASF Ultrasint® PA6 LM, especially for customers who already operate standard LS equipment, but want to take advantage of the superior properties of PA6 LM – it shows outstandingly high printer compatibility and comes at a competitive price.

#2 Which properties make BASF Ultrasint® PA6 LM a special material?

FE: When developing Ultrasint® PA6 LM, our objective was to create a special powder material designed to maximize production accessibility to any customer using the Powder Bed Fusion technology. Thanks to a lower melting temperature, it enables lower processing temperatures of 170 - 180°C compared to common PA6 – achievable by any PBF equipment.

Process of Powder Bed Fusion

The innovative technology of powder bed fusion opens up new possibilities in part production. This type of additive manufacturing enables the creation of three-dimensional solid objects in any shape imaginable directly from digital CAD data. Thin layers of powder particles are locally fused, e.g. by a laser, and built up layer by layer into the desired shape. (See figure)

1. A thin layer (typically 0.1 mm thick) of powder is deposited in the workspace.
2. The powder is heated up and locally fused by a laser.
3. The powder bed is lowered by one layer thickness and the process repeats until the parts are finished.

By using PA6 LM on existing machines, prototyping companies and end-users are able to take advantage of PA6-like properties without additional investment in high-temperature LS equipment. That was important to us.

Balanced Property Profile of PA6 LM

In addition, the material proves a balanced property profile, combining superior mechanical performance with outstanding thermal resistance. It can be used to print components with:

• High impact strength
• High modulus
• Higher heat resistance
• Excellent thermal distortion stability

PA6 LM is best suited to industrial applications where enhanced mechanical properties are needed at low printing temperatures.

A quite special is the in-particle filler technology:

• Our Ultrasint® PA6 LM contains a mineral filler which provides mechanical reinforcement.
• By using this in-particle filler technology, achieving homogenous end products with higher isotropy and reliability becomes very easy.
• The embedded filler also allows easy material handling, improves powder recycling and eliminates the risk of demixing.
• To top it off, the material allows easy post-processing, including coating, milling, and grinding.

To sum it up, we are able to say: Ultrasint® PA6 LM enables real-world injection molding PA6 performance and is easily processable on any PBF equipment.

#3 Do you see certain industries where Ultrasint® PA6 LM brings special benefits and added value?

FE: Definitely. Generally speaking, Ultrasint® PA6 LM is highly versatile and enables a wide range of applications, from prototyping to industrial serial production. Some applications to mention are, for example, functional prototypes for the automotive industry, such as:

• Parts in the engine compartment
• Painted exterior parts
• Engine oil systems

The material is also perfectly suitable for high-performance spare parts, multi-purpose industrial goods, or durable & rigid jigs and fixtures.

#4 What makes Forward AM by BASF the most preferred partner for the Additive Manufacturing Industry?

FE: We have the backing from BASF – giving us staying power and our customers the reliability and security they need for long-term planning in a fast-evolving market. With our access to the full spectrum of BASF's material know-how and our extensive end-to-end services portfolio, we are able to offer a one-stop portfolio with all the tools needed to succeed in 3D printing, from:

• Testing
• Validating components to process optimization, and
• A comprehensive range of high-performance 3D printing materials

All with the aim to enable our customers to shape the Additive Manufacturing industrial revolution.


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