Polycarbonate 3D Printing: Hype or High Performance?

Polycarbonate (PC) is a thermoplastic best known for its strength and durability in 3D Printing service. Used in the making of bulletproof glass, polycarbonate is lightweight yet extremely tough. It is naturally transparent and exhibits a high resistance to heat and impact which makes it a popular choice of material in 3D printing in India.  This article will provide you with all that you need to know about polycarbonate 3D printing services. 

WHY CHOOSE POLYCARBONATE FOR PRINTING?

Polycarbonate (PC) filament is a tough material which has some advantages over printing with other filaments like PLA and ABS.  The durability and flexibility of the PC are higher than that of PLA but lower than nylon. It is lighter and less dense than ABS, while also exceeding ABS, PLA or PMMA in strength.  Polycarbonate has an extremely high resistance to heat and its structural integrity remains intact at temperatures as high as 150° C (whereas PLA begins to deform at 60°C), which makes it suitable for use in high-temperature applications.  It is flexible enough to be bent without breaking at room temperature and can handle more torsional stress than other thermoplastics. 

WHAT ARE THE CHALLENGES WHILE POLYCARBONATE 3D PRINTING?

Although PC has many desirable qualities required for high-quality and affordable 3D printing services, certain properties make printing with this thermoplastic quite difficult.  Polycarbonate, like nylon, is hygroscopic. This means that it absorbs moisture from the air. Because of this, it needs to be stored in an air-tight, moisture-free environment after opening otherwise its printing performance, as well as the strength, will be affected.  Another challenge is that it requires very high temperatures for 3d printing online. If printed at a temperature too low or with excessive cooling, it will extrude poorly and the layers will not have proper adhesion. It is also more prone to warping and shrinkage.  Nonetheless, if you have the right printer capable of providing the required high-temperature conditions for PC with an enclosed build volume, you have nothing to worry about. 

BEST PRACTICES AND TIPS FOR POLYCARBONATE 3D PRINTING

PEI is generally the best build surface for polycarbonate, as it can consistently stick at 110°C or higher. In contrast, other surfaces can start to break down or permanently adhere to the print. Once the bed has cooled, polycarbonate typically self-releases or can be easily removed with a spatula and minimal effort. With the extreme printing temperatures and low level of active cooling required, polycarbonate is prone to stringing and oozing. To counter this, try increasing the retraction distance and speed settings or enabling the coasting setting. The high temperatures used to print polycarbonate tend to be very poor at bridging or printing overhangs. Always make sure you have suitable support structures. We also recommend increasing the level of infill to provide adequate support to the top layers. This should also be a layer or two thicker than normal to prevent any drooping.

ADVANTAGES

• High heat and impact resistant
• Naturally transparent
• Bendable without breaking

DISADVANTAGES

• Requires very high print temperatures
• Prone to warping and oozing
• Extremely hygroscopic

WHICH IS THE RIGHT 3D PRINTER FOR POLYCARBONATE 3D PRINTING?

As you now know, it’s not easy to 3d print online with polycarbonate. But the right 3D printer for polycarbonate can make your life a lot easier. 

But what is the right printer? 

As said, polycarbonates require extremely high temperatures for 3D printing service in India. So the right 3D printer would be one that can reach and maintain high hot end and bed end temperatures. Also, it’s important to keep the printer in an enclosure to ensure stable heat.  One more thing to keep in mind while choosing the right printer for Polycarbonate 3D Printing in India is that polycarbonates have a hard time sticking to anything. The best surface to use while printing with polycarbonate is polycarbonate.  If using other surfaces like borosilicate glass, you require large amounts of adhesives like Cyanoacrylate to avoid the print from getting warped and being pulled off the heated bed.

WHAT ARE THE THINGS TO KEEP IN MIND WHILE POLYCARBONATE 3D PRINTING?

Now we will look at certain tips and tricks that are essential if you want a perfect polycarbonate 3D print online. 

• Moisture 

As discussed, PC is hygroscopic and so it needs to be kept dry when not in use so that it doesn’t absorb atmospheric moisture. This is essential because if the filament is even a little wet, it will result in bad quality prints.  You should always consider drying your filament before using it for online 3D Printing, even if you’ve kept it in an air-tight container because being safe is better than sorry. Even a small amount of moisture in the filament can vaporize during printing to create bubbles in the print which can make your prints less durable and cloudy. It also affects the transparency of the final print. 

• Nozzle Temperature

While 3D printing with polycarbonates, the minimum hot end temperature required for best results is between 290°C and 300°C. This temperature can be lowered if you’re working with a composite PC but it is inferior in quality to pure polycarbonate.  Hot end temperatures beneath 290°C or even slow printing speed can result in jamming. That is why it’s important to know the specifications of the 3D printer you will be using beforehand.

• Ambient Temperature

Another pointer to keep in mind is that if a consistent bed temperature is not maintained, polycarbonate can warp and shrink.  The bed should reach and maintain temperatures between 135 and 150°C to avoid shrinkage and warping.  Effective bed adhesion is also very important when working with PC 3D Printing quote. When the material cools down, it could separate or crack if the layers do not stick together properly. To ensure this, you should maintain the ambient temperature by properly enclosing the printer. That is why an enclosure is important while 3D printing bangalore with polycarbonate.

WHAT ARE THE APPLICATIONS OF POLYCARBONATE 3D PRINTING?

Polycarbonate is widely used in the manufacturing of many products. Recently there was a lot of debate around the use of polycarbonate for making baby bottles. This was because the PC is said to release bisphenol A particles which are harmful to our health, and so using this in baby products is not ideal.  Some countries have even banned the use of PC in manufacturing baby bottles. Polycarbonates are also known to cause a large amount of pollution in the environment.  But by using polycarbonate for 3D printing services in India, we can promote the possibility of recycling this thermoplastic. Thanks to its durability and transparency, even recycled PC can be used to make functional prototypes and beautiful designs.  PC, being originally transparent, is also used to prototype windows, production of optical glass, motorcycle helmets and bulletproof windows. Manufacturing these products using other materials would be costlier and so polycarbonate is also saving money.  The high heat resistance of polycarbonate makes it an excellent choice to create functional prototypes where other materials like ABS would warp under heat or stress. 

Watch: https://www.youtube.com/watch?v=xxOd_cvjH9g

FAQs

Why Should You Store A Polycarbonate Filament In An Air-tight Container?

A polycarbonate filament is hygroscopic, meaning it absorbs more moisture from the air than usual which can affect its printing performance and its overall strength. It is recommended to store these filaments in a moisture-free and air-tight container after opening for 3D Printing services. What Prints And Products Are The Most Commonly Made Of Polycarbonate Filaments? Because of its main features which are high resistance to heat, incredible toughness, and optical clarity, people commonly use it in creating prints such as:

• DVDs
• Riot shields
• Safety glasses
• Bulletproof glass

How Strong Is The Polycarbonate Material?

This material can be bent without damaging or breaking it, that is why it is mostly used in applications that need minor flexibility.

On What 3D Printer Is A Polycarbonate Filament Best Used?

Polycarbonate is best printed on a machine that features an enclosed build volume and can withstand high temperatures from the printer bed to its extruder. What Are The Factors To Consider When Using A Polycarbonate Filament?

• Always remember that polycarbonate material needs high temperatures to extrude properly.
• Note that polycarbonate is prone to shrinkage and warping, so excessive cooling should be avoided.
• Polycarbonate is hygroscopic making it absorb more moisture than usual and can damage itself.

Until What Temperature Can A Polycarbonate Filament Withstand?

Having a high glass transition temperature of 150C (302F), a polycarbonate filament can maintain its structural integrity up to the indicated temperature, making it perfect for Online 3D Printing applications that require high temperatures. It can withstand that temperature because it requires an extremely high temperature when printing; if it is printed at a lower temperature, it will exhibit layer separation.

What Are The Benefits Of Using Polycarbonate 3D Printing?

• It has high heat resistance for affordable 3D Printing services; it can withstand the temperatures up to 135C (275F) compared to standard PLA filaments that begin to deform at 60C (140F).
• Its high durability, making it widely used on things such as bulletproof glass, riot shields, and more.
• Because of its strong nature and high durability, it is resistant to high impacts and shattering.
• It is moderately flexible therefore it is widely used in the field of engineering.
• Its transparent material makes it aesthetically pleasing and that is one of the reasons why this material is commonly used in glasses.
• It is electrically non-conductive.

How Hard Is It To Use Polycarbonate Filaments in 3D Printing?

People may wonder that with this filament’s superior qualities why doesn’t everyone use it in 3D printing in India? It is because a polycarbonate filament is not an easy material to work with, to successfully print the material, one should have a high-quality polycarbonate filament paired up with a high-performance desktop 3D printer that can print and withstand high temperatures.

What Is The Proper Ambient Temperature Of Polycarbonate Materials?

Since the material is prone to warping and shrinkage, maintaining the proper ambient temperature is needed for efficient online 3D Printing services. Making a heated printer bed essential it should emit a temperature of 135C to 150C (275F to 302F).

What Are The Hardware Requirements When Using A Polycarbonate Filament?

Since polycarbonate filaments are harder to use, 3D Printing companies should make sure that their 3D printers meet the hardware requirements for polycarbonate to ensure the best quality of 3D Print online.

• 3D printer bed – A heated bed is required since polycarbonate filaments need high temperature in its printing process, the heated bed should be able to emit a temperature of 80C to 120C (176F to 248F) and an enclosure on the printing device is required also.
• Build plate or Build surface – The 3D Printing companies must make sure to have Commercial Adhesive, PEI (Polyetherimide) that is commonly used as a building surface for all 3D printers, and a glue stick.
• Extruder – Used to complete the extrusion process needed. An all-metal hot end is required, and it should be able to emit and withstand a temperature of 260C to 310C (500F to 590F).
• Cooling – Since a polycarbonate filament is prone to warping and shrinkage and relative lower temperatures, a part cooling fan is not required for this material.

What Type Of Build Surface Is Appropriate For Polycarbonate 3D Printing?

PEI (Polyetherimide) is the best build plate or surface for a polycarbonate filament used by 3D Printing companies Bangalore. Standard build plates have commercial adhesives and glue sticks break down at the high temperatures required to print Polycarbonate. A PEI sheet can consistently hold on to Polycarbonate at 110C (230F)

How Many Top Layers Should You Use When Printing This Material?

Due to the high temperatures needed, the extruded filament will droop if it is not supported. 4 layers should be used to ensure the top layers are smooth. It is recommended to print solid infill layers slowly so they can successfully bridge the space between the infill lines.

CONCLUSION

Polycarbonate is the strongest filament that can be used for online 3D Printing Bangalore. It has a tensile strength, durability and heat resistance which makes it the ideal option for creating high-strength, functional components. However, working with polycarbonate for online 3D Printing India is not the easiest but by following this article word-to-word and proceeding in the right manner and keeping all the tips and tricks in mind, you can get the best results possible. 

 Happy Printing!

Read More: Why You Should Consider 3D Printing for Production Runs