New PTFE-free 3D printing resin

Many manufacturers of laboratory technology, diagnostic devices and surgical robots produce plastic components using 3D printers, such as miniature gears, rotating valves or pivoting levers. This saves them time and money. The problem is that many printing materials contain so-called PFAS chemicals. And the EU could restrict these in the future due to the potential risk to people and the environment. "Many manufacturers in sensitive industries such as medical technology are therefore already looking for alternative 3D printing materials," says Jonas Burk, Head of Additive Manufacturing at Igus. "One such alternative is our new iglidur i2000, a 3D printing material that does not contain any of the 96 PFAS substances considered critical in concentrations above 0.1 percent by mass."

Self-lubricating effect without PTFE

The new 3D printing material is a resin, a liquid, light-sensitive synthetic resin that SLA and DLP printers cure layer by layer with UV light to create three-dimensional plastic objects. "Iglidur i2000 makes it possible to print components with smooth surfaces with the highest precision and in a quality comparable to injection molding," says Jonas Burk. The material is particularly suitable for moving and friction-loaded components, such as smaller drive and gear wheels or bearing bushes.

A special feature of the material is that it is lubrication-free. Solid lubricants are integrated into the resin for low-friction and hygienic dry running without grease. Whereas Igus previously used PTFE, a chemical from the PFAS group, for this self-lubricating effect, a PTFE-free variant is used in Iglidur i2000. "Users can therefore print components as usual without having to worry about PFAS regulations," explains the 3D printing expert.

122 times more wear-resistant than a standard resin

Iglidur i2000 proves to be extremely mechanically resilient and durable. A flexural strength of 74 MPa ensures stability, while a Shore D hardness of 80 ensures high resistance to wear. The material is also thermally robust. It can permanently withstand temperatures from -20 °C to 100 °C and can even withstand temperatures of up to 140 °C for short periods. Iglidur i2000 was able to demonstrate its high wear resistance in the test laboratory. A stainless steel test specimen was moved over the resin surface at a speed of 0.5 m/s and a surface pressure of 1.4 MPa. "The wear rate fell from 63.97 µ/km with a standard resin to just 0.52 µ/km. This corresponds to an improvement by a factor of 122," emphasizes Jonas Burk.