Best High-Temperature 3D Printing Filaments

Introduction

Filaments designed for high-temperature 3D printing are crucial in producing components that can withstand extremely high levels of thermal stress or retain their original properties. The new Advanced Materials prove to be essential for companies and aerospace, Automotive, manufacturing, and medical. These components endure high temperatures, as well as mechanical loads and chemical exposure.

Technology Overview 

Semi-crystalline polymers (e.g., PEEK & PEKK) are highly ordered and provide excellent resistance to heat, mechanical strength, chemical stability, etc. They are best suited for extreme use and can only be printed with specialized printers with hotends capable of 360–400°C and heated beds (120–150 °C).

● Semi-Crystalline Polymers (e.g., PEEK, PEKK):  

These types of high-temperature materials have an extremely ordered molecular structure. This ordered structure results in an exceptional heat resistance and also enhances mechanical strength and chemical stability. These types of materials are suitable for extreme environments that require specialized 3D printers with hot ends reaching over 360 to 400° Celsius and heat beds at ranges between 120 and 150 degrees Celsius.

○ Pros: High HDT Heat Deflection Temperature  (~280°C), has superior tensile strength (up to 100 MPa). The filament has excellent chemical resistance and high tensile strength, plenty suitable for applications for medical implants and air space components.

○ Cons: High cost ($500–$1000/kg), High-end industrial 3D printers, which use heated chambers for filaments, are prone to warping if cooling is not controlled. Prints require a complex post-processing method after the fact.

● Amorphous Thermoplastics (e.g., PEI, Polycarbonate):

The material lacks a crystalline structure but offers easier printability. It is also good for heat resistance for prosumer-grade 3D printers.  Even though they are less rigid than the semi-crystalline polymers, they provide really good impact resistance and affordability.

○ Pros: More affordable ($50–$300/kg), compatible with prosumer printers (hotends of 260–340°C). This type of material, compatible with prosumer printers, offers less warping and good impact resistance than the semi-crystalline materials.

○ Cons: Lower HDT (140–210°C). This type of material has reduced chemical resistance compared to PEEK/PEKK, and is hydroscopic in nature, requiring drying out before use to prevent defects

Product Comparison

1. 3DXTECH ThermaX™ PEEK (Price: ~$595/kg)

● Key Specs: HDT ~280°C, Tg 143°C, continuous use up to 250°C, prints at 360–400°C hotend, 120–145°C bed, semi-crystalline structure, tensile strength ~100 MPa.

● Best For:  Professionals in aerospace, medical, or oil & gas industries requiring the highest level of thermal resistance and durability.

● Pros: Unmatched thermal stability in extreme environments, high strength-to-weight ratio, comparable to metals, biocompatible for medical grafts and implants, resistant to solvents and hydrocarbons.

● Cons: Expensive, limiting accessibility, requires industrial-style printers (e.g., Stratasys F900, Intamsys Funmat HT), and warping can be a concern if precise temperature control and enclosed chamber characteristics are not maintained.

PEEK is the gold standard material in high-temperature 3D printing and is being used in applications like aircraft ducting and surgical implants. The high price tag of PEEK material represents the unique properties of the material that are extremely useful or required to meet regulatory standards.

2. Essentium PEKK (Price: ~$600/kg)

● Key Specs: HDT ~280°C, Tg ~160°C, continuous use limit 260°C, printing hotend temp of 360–400°C and bed temp of 120–150°C, semi-crystalline, ultimate tensile strength of ~95 MPa.

● Best For: Users in the industrial aerospace and automotive industries looking for PEEK-like performance while being easier to print.

● Pros: Slightly higher continuous-use temperature than PEEK, better layer adhesion due to less crystalline content than PEEK, and great chemical resistance for harsh environments.

● Cons: Similar cost to PEEK, needs an industrial-grade printer, and limited suppliers may limit access to the material.

PEKK is a strong alternative to PEEK if you need a similar set of thermal and mechanical properties but want to use an easier-to-print material.

3. SABIC ULTEM 9085 (Price: ~$300/kg)

● Key Specs: HDT 170 - 210 °C, Tg ~217 °C, continuous use 170 °C, prints 340 - 400 °C hotend, 120 - 150 °C bed, amorphous, tensile strength ~90 MPa, flame-retardant.

● Best For: Aerospace and automotive professionals looking for heat-resistant, flame-retardant parts, with a lower price than PEEK.

● Pros: Flame retardant material with UL94 V-0 rating, biocompatibility with food contact certification, lower cost than PEEK/PEKK, retains good thermal performance.

● Cons: Requires an industry printer, cracking concerns if not printed in an enclosed chamber, less heat resistant than semi-crystalline polymers.

ULTEM 9085 is great for applications such as: Aircraft heat shields, automotive under-hood components, thick-walled products, for those using an industrial printer, and do not require maximum thermal performance.

4. BASF Forward AM Ultrafuse PAHT CF15 (Price: ~$120/kg)

● Key Specs: HDT ~150°C, Tg 72°C, continuous use up to 150°C (180°C short-term), prints at a hot end temperature of 260–280°C, 100–120°C bed temperature, 15% carbon-fiber-reinforced, tensile strength ~80 MPa

● Best For: Prosumer and industrial use with strong, heat-resistant parts on mid-range printers

● Pros: High stiffness and strength from carbon fiber; compatible with prosumer printers (e.g., Creality K1C and Bambu Lab X1C); some resistance against oils and grease.

● Cons: Reasonable, but not ideal, heat resistance compared with PEEK/PEI; high level of hygroscopicity warrants drying the filament; carbon fiber increases the wear rate of the nozzle.

If you have a prosumer printer, you should seriously consider PAHT CF15, which is a great, cost-effective option for people looking for durable and heat-resistant parts, such as gears or automotive parts.

5. Polymaker PC-Max (Price: ~$38/kg)

● Key Specs: HDT ~140°C, Tg 150°C, can continuously operate up to 140°C, print hotend 260–310°C, print bed 80–120°C, amorphous, ultimate tensile strength ~70 MPa, optically transparent.

● Best For: Hobbyists and prosumer users looking for an affordable filament solution that leads to heat-resistant parts with decent impact strength.

● Pros: Affordable, high impact resistance, optical clarity for aesthetic purposes, and prints are available on some mid-range printers if they have enclosures.

● Cons: Less heat resistant than PEEK/PEI, objects will warp without an enclosed chamber, and moderate chemical resistance limits use in very harsh environments.

Polycarbonate is a very versatile filament and cost-effective for applications such as safety helmets and automotive lenses that many prosumer users can access.

Comparison Table

Analysis: Semi-Crystalline vs. Amorphous Filaments

● Efficiency: Semi-crystalline filament types (PEEK, PEKK) have superior heat resistance (HDT~280°C) and superior strength compared to their amorphous counterparts making them more suitable for applications with importance such as aerospace components or medical implants. There is more stability when semi-crystalline filaments are subjected to extreme heat or chemical strain because their molecular structure is ordered. While amorphous filaments (PEI, Polycarbonate) are generally easier to print due to the lower chance of warpage, better layer adhesion, and lower HDT (140–210°C) making more accessible for incorporation into prosumer printers or products that were low on importance.

● Cost: Semi-crystalline filaments are a lot more expensive ($500-600/kg) and require industrial printers and professional-grade filament with capability for higher-temperature nozzles and enclosed chambers. However, the amorphous alternatives available such as polycarbonate ($50/kg) and PAHT CF15 ($120/kg),

● Use Case: Semi-crystalline filaments are best for high-stakes applications that require extreme heat resistance (i.e., aircraft engine parts, chemical processing equipment). Amorphous filaments could be suitable for prototyping, can be used to produce OEM automotive parts, and for consumer products where only moderate heat resistance is required (100–170°C). PAHT CF15 offers a good in-between solution that provides industrial-grade durability for a prosumer printer.

Further factors to consider include moisture sensitivity (all filaments can benefit from drying before printing) and printer compatibility.

Recommendations

● Best Overall: 3DXTECH ThermaX™ PEEK, for its Heat Deflection (HDT ~280°C) and mechanical properties, makes it the best for your critical aerospace, medical, and oil and gas applications.

● Best Budget: Polymaker PC-Max, for its price ($50/kg), prosumer printing capabilities, and good heat resistance (HDT ~140°C), makes it ideal for hobbyists and businesses looking for durable and impact-resistant parts.

● Best for Industrial Applications: Essentium PEKK, for its thermal performance similar to PEEK (continuous use up to 260°C), allows for improved printability.

● Best for Prosumer Users: BASF Forward AM Ultrafuse PAHT CF15 for the combination of heat resistance (HDT ~150°C), high stiffness, and the fact that it works with prosumer printers.