The lack of isotropic strength between layers has traditionally been the bane of 3D printing, particularly fused deposition modeling (FDM).
Now, a collaboration between Zymergen (Nasdaq: ZY), Hexagon (Nasdaq Stockholm: HEXA B), 3D4Makers, and AON3D has demonstrated high isotropy and strength in a new polyimide formulation.
A part made from Zymergen’s Z2 Polyimide filament was able to withstand 432 kg of load before failure in tests supported by The Royal Netherlands Navy’s Expertise Centre Additive Manufacturing (ECAM).
Polyimide,
not to be confused with polyamide (Nylon), is a much stronger thermoplastic manufactured by Zymergen.
The company’s role in AM is noteworthy, as the publicly traded company reportedly had commercialization issues before being acquired by Ginko Bioworks this year.
On an AON M2+ high-temperature 3D printer,
a tie-down bracket for military cargo planes was 3D printed with 100 per cent infill from Z2 Polyimide.
The material is said to have a tensile modulus similar to ULTEM 9085,
a SABIC 3D printing material commonly used in aerospace.
However,
Zymergen’s filament has higher strength and elongation at break than ULTEM, potentially indicating improved interlayer weld strength and part isotropy.
extreme isotropy for FDM polymer parts
Before running tests with the ECAM, the team simulated its performance in Hexagon’s Digimat AM software. Instead of a single layer, the tool predicted a fracture across multiple layers.
The part withstood a 432 kg load before fracturing through multiple layers in two locations, exactly as Digimat predicted.
The team was able to validate that Z2 Polyimide exhibits extreme isotropy for FDM polymer parts because the component broke due to stress across the entire structure rather than just inter-layer welds.
Before running tests with the ECAM,
the team simulated its performance in Hexagon’s Digimat AM software.
Instead of a single layer, the tool predicted a fracture across multiple layers.
The part withstood a 432 kg load before fracturing through multiple layers in two locations, exactly as Digimat predicted.
The team was able to validate that Z2 Polyimide exhibits extreme isotropy for FDM polymer parts because the component broke due to stress across the entire structure rather than just inter-layer welds.
Boom for the 3dprinted polymer market
SmarTech Analysis estimates that the market for 3D printed polymer components will be worth $26 billion by 2030 in its Polymer Parts Produced:
AM Applications Market Analysis report.
According to the same report, the aerospace sector will grow from 6.4 per cent of the total in 2021 to 11.5 per cent by 2030.
The improved varieties of plastics that enter the market will be a key driver of this growth.
Consider how much 3D printing adoption could increase in aerospace if the sector was limited to ULTEM alone.
Moving towards a green world
Importantly, in March, Saudi Oil Minister Prince Abdulaziz bin Salman stated that the world is
“running out of energy capacity at all levels.”
Recently,
Amin Nasser, CEO of Saudi Aramco, stated that the world’s capacity for oil is “extremely low.” As oil becomes more difficult to obtain, raising its overall cost, the price of ULTEM and other fossil fuel-based polymers will rise as well.
Because Z2 Polyimide is said to be “bio-inspired” and created through “bioengineering,”
it implies that, while fossil fuels may still play a role, the materials may have a biopolymer basis.
If Z2 can be manufactured as a pure biopolymer, it will not only be less expensive than ULTEM, but it will also be better for the environment.
