RMS - Fortus 450mc Ultem 9085 Material 3D Printing

This tutorial is to ensure a better experience printing on the Fortus 450mc, with the Ultem material. Ultem is the newest material that we have experimented with at the Autodesk Pier 9 3D printing lab this past week. The material is also known as the Ultem 9085, which is the strongest material that one could use for 3D printing at the Pier 9 labs. The material information could be found here - http://www.stratasys.com/materials/fdm/ultem-9085

According to the Stratasys website the material is best for the highest precision for prototyping and available in tan or black. So far, we really enjoyed using the tan color, which gives the material a golden gloss.

"3D print high-performance parts in tan or black

A reputation for reliability. This famously overachieving thermoplastic has well-rounded thermal, mechanical and chemical properties that make it superior in most categories. ULTEM 9085 is an FDM thermoplastic ideal for aerospace, automotive and military applications because of its FST rating, high strength-to-weight ratio and existing certifications. It empowers design and manufacturing engineers to 3D print advanced functional prototypes and production parts. - See more at: http://www.stratasys.com/materials/fdm/ultem-9085...

This instructable is based on a prototype designed for the Resilient Modular Systems, PBC Modular Brick Unit.
Resilient Modular Systems is a Public Benefits Corp, and leader in innovative sustainable modular components for the building industry in emerging markets.

More information - http://resilientmodularsystems.com
Facebook - https://www.facebook.com/ResilientModularSystems
Twitter - http://twitter.com/RModularSystems

Designed by - Wendy W Fok | Founder
Resilient Modular Systems, PBC

Step 1: Settings for Insight Version 6

A) First to note is that, from our experience (Gabe and I), the support materials that come out of the Fortus 450mc using Ultem is very difficult and almost impossible to dissolve with the current dissolving solution within the Pier 9 labs. Therefore, make sure that the settings are correctly set up, otherwise, the print will not work as well. It would be also suggested that the support materials are limited in use, for the ease of removing the materials after the print is complete.

B) the printing temperature for the Ultem is also higher in temperature, and requires the T16 / T16 tip.

C) when you're preparing the files for the 3D print on the Fortus 450mc, that the settings for the Ultem prints are slightly different than the general prints for ASA.

Step 2: Support Material and Tool Path Generation

A) Different from printing ASA materials, the Ultem material offers a fourth setting on the set-up.

B) The support material, after a few experimentation, is best set as "sparse", this would allow users to remove the support while it's hot more easily.

C) Another option is to set up the support as "box", this would also allow an easier removal after the prints are out.

D) Also make sure that if you are printing prototypes with thinner walls to set up "System Mode" with the "thinner wall" setting, rather than "normal".

Step 3: Control Center Set Up

Make sure that the settings within the Control Center is set up for the Ultem Material, and that the tips are correctly set up . The more important information to follow-up on is whether the tips and the heat are correctly set.

Step 4: Finishing / Removing Support Material

As mentioned previously, Ultem is a high temperature printing material. Therefore, it would be suggested that the support material be removed fresh out of the oven. Use gloves, and remove each prototype individually, to ensure that you only remove the pieces that you would like to clean out. This way, you would have the other pieces within the oven, baking and kept hot, while you are removing the build support materials individually. Keeping the support materials hot would allow you to remove the support materials easier.

*Note: the prints that come out of Ultem materials are much hotter than various other ASA materials. It would be suggested that you wear gloves throughout the support removal process.

This instructable is based on a prototype designed for the Resilient Modular Systems, PBC Modular Brick Unit.

Resilient Modular Systems is a Public Benefits Corp, and leader in innovative sustainable modular components for the building industry in emerging markets.

More information - http://resilientmodularsystems.com
Facebook - https://www.facebook.com/ResilientModularSystems
Twitter - http://twitter.com/RModularSystems

Designed by - Wendy W Fok | Founder
Resilient Modular Systems, PBC