SABIC ULTEM™ AM9085F

SABIC ULTEM™ 9085 resin is an amorphous high-flow polyetherimide blend, commonly used in prototyping, tooling, and production parts. Produced from SABIC ULTEM™ 9085 resin, SABIC ULTEM™ AM9085F filament offers long-term heat resistance and stability of physical and mechanical properties at elevated temperatures for extended periods.

Due to its heat resistance, high impact strength, and high strength-to-weight ratio properties, ULTEM™ AM9085F is widely used in aerospace, automotive, and military applications.

Printing Difficulty: Challenging/Expert

ULTEM™ AM9085F can be purchased from AON3D directly by contacting help@aon3d.com.

Technical Specifications

Material Safety Data Sheet

Technical Data Sheet

For more information on material safety and specific material properties, see the manufacturer’s website.

Physical Properties

Property Value Test Method
Density 1.275 g/cm³ ASTM D792

*All data as reported by SABIC Technical Data Sheet as downloaded on 25/8/2020. Print conditions listed on the Technical Data Sheet.


Usage Notes

General Process Settings

For best results, process settings should be adjusted based on model geometry. If you require process development support, our Applications Engineering team can help! Send us a message at help@aon3d.com to consult with one of our Additive Manufacturing Specialists.

Optimal extrusions are visually light-honey whereas degraded material may extrude as light-brown extrusions. Print with low volumetric flow rates. Use a nozzle size of at least 0.40 mm with moderate printing speeds between 20-60 mm/s for optimal mechanical properties and print quality. Part warpage and/or deformation may occur if internal stresses are not sufficiently managed; induced stress by polymer shrinkage. Higher extrusion temperatures and slower printing speeds help the polymer flow more easily, decreasing the accumulation of stress between each layer. Thus, interlayer welding strength increases but polymer degradation may occur from extremely high extrusion temperatures, especially if the printing speed is very slow.

Surface Example

Limit the use of ULTEM™ AM9085F to small parts or low-mass parts (low infill, <20%, or made of only thin walls, 1-3 mm).

Larger models of high infill percentages may be difficult to print. Layer adhesion will be difficult to control as the previous layer may lose too much heat due to slow printing speeds and internal stresses may cause poor interlayer welding. ULTEM™ AM9085F tends to shrink and warp easily; ideally, extrude at the lowest temperature in the highest chamber temperature possible.

Setting AON-M2
Extrusion Temperature 360-390ºC
Bed Temperature 170ºC
Chamber Temperature 120ºC
Print Speed 20-60 mm/s
Nozzle Size 0.40-1.00 mm
Build Platform High-Temperature Build Plate

The AON-M2 is unable to reach chamber temperatures above 120ºC. This constraint may limit your ability to optimally print ULTEM™ AM9085F. The AON-M2 2020 and AON M2+ can reach chamber temperatures up to 135ºC, contact AON3D directly at help@aon3d.com for more information.

Setting AON-M2 2020
Extrusion Temperature 360-390ºC
Bed Temperature 170ºC
Chamber Temperature 135ºC
Print Speed 20-60 mm/s
Nozzle Size 0.40-1.00 mm
Build Platform High-Temperature Build Plate
Setting AON M2+
Extrusion Temperature 360-390ºC
Bed Temperature 155ºC
Chamber Temperature 135ºC
Print Speed 20-60 mm/s
Nozzle Size 0.40-1.00 mm
Build Platform PEI build sheet single-use (multiple uses with Nano Polymer Adhesive)

Sample Slicer Profile

Single Extruder, 0.40mm nozzle

Single Extruder, 0.60mm nozzle

Moisture Control

ULTEM™ AM9085F is extremely susceptible to moisture uptake. Bubbles, popping noises, excessive oozing, rough texture, and stringing may occur if it has been hydrated.

The filament can be dried in a convection oven at 120ºC for at least 6-8 hours before processing and fed from a low humidity environment. When not in use, store in a sealed package or container with silica desiccant to inhibit moisture absorption. Properly dry the material before adjusting process parameters to obtain reliable and consistent results. Our drybox setup prevents filament moisture uptake to keep the material printing process free of moisture, contact help@aon3d.com for more information.

For more information, see the Filament Drying and Moisture Control guide.

Build Platform Adhesion

For instructions on how to inspect the AON3D build plates, refer to the Inspect and Clean Build Plates procedure.

Build Platform Selection

ULTEM™ AM9085F prints best on the High-Temperature Build Plate.

First Layer Adhesion

Generally, ULTEM™ AM9085F adheres so well to the High-Temperature Build Plate that parts and/or the build platform may get damaged during part removal as shown below.
A sacrificial temperature gradient raft may be used to reduce bed adhesion, protecting the part and/or build platform.

Build Platform Damage

The first layer can be printed at a slightly lower extrusion temperature, then gradually increased in the raft until it meets the bottom of the part’s surface. The temperature gradient must be small and occurs over many layers to reduce print warpage by decreasing the stress gradient in the part. Fine-tuning the temperature gradient and printing speed will make the part release from the raft easily. Printing the raft this way will compensate for toolhead expansion. Increasing/decreasing thick and thin raft layers will affect raft ease of removal.

For example, the table below illustrates a possible temperature gradient using a raft with 1 thick and 2 thin layers to reduce first layer adhesion but adequate interlayer adhesion:

Layer Number Extrusion Temperature Raft Layer Type
1 360ºC Base - Thick
2 365ºC Top - Thin
3 370ºC Top - Thin
4 370ºC First Layer of Part
5 380ºC Second Layer of Part

If the thin raft is difficult to remove from the bottom layer of the part, lower the extrusion temperature and/or increase the Separation Distance to decrease the adhesion between the two interfaces. Be cautious as the internal stresses within the part may accumulate enough to cause warping if you try to reduce the adhesion between the raft and the bottom layer of the part too much.

Start with a First Layer Height and First Layer Width of 100-120% for both and adjust until desired bed adhesion is achieved.

First Layer Extrusion Temperature First Layer Speed
350-360ºC 20 mm/s

Anchor Tabs

For warp-prone geometries that consistently warp even with first layer optimization, anchors may be added onto localized regions of the part. As shown above, anchor tabs were added to the part to reduce warping at the corners. The 90 degree corner(s) was/were susceptible to extreme warping. A custom sacrificial raft was added to reduce the risk of part delamination and damage onto the part. Combining these additional features reduces warping and avoids part and/or build platform damage.

For more information, see the Build Platform Adhesion guide.

Build Platform Selection

ULTEM™ AM9085F prints best on the High-Temperature Build Plate.

First Layer Adhesion

Generally, ULTEM™ AM9085F adheres so well to the High-Temperature Build Plate that parts and/or the build platform may get damaged during part removal as shown below.
A sacrificial temperature gradient raft may be used to reduce bed adhesion, protecting the part and/or build platform.

Build Platform Damage

The first layer can be printed at a slightly lower extrusion temperature, then gradually increased in the raft until it meets the bottom of the part’s surface. The temperature gradient must be small and occurs over many layers to reduce print warpage by decreasing the stress gradient in the part. Fine-tuning the temperature gradient and printing speed will make the part release from the raft easily. Printing the raft this way will compensate for toolhead expansion. Increasing/decreasing thick and thin raft layers will affect raft ease of removal.

For example, the table below illustrates a possible temperature gradient using a raft with 1 thick and 2 thin layers to reduce first layer adhesion but adequate interlayer adhesion:

Layer Number Extrusion Temperature Raft Layer Type
1 360ºC Base - Thick
2 365ºC Top - Thin
3 370ºC Top - Thin
4 370ºC First Layer of Part
5 380ºC Second Layer of Part

If the thin raft is difficult to remove from the bottom layer of the part, lower the extrusion temperature and/or increase the Separation Distance to decrease the adhesion between the two interfaces. Be cautious as the internal stresses within the part may accumulate enough to cause warping if you try to reduce the adhesion between the raft and the bottom layer of the part too much.

Start with a First Layer Height and First Layer Width of 100-120% for both and adjust until desired bed adhesion is achieved.

First Layer Extrusion Temperature First Layer Speed
350-360ºC 20 mm/s

Anchor Tabs

For warp-prone geometries that consistently warp even with first layer optimization, anchors may be added onto localized regions of the part. As shown above, anchor tabs were added to the part to reduce warping at the corners. The 90 degree corner(s) was/were susceptible to extreme warping. A custom sacrificial raft was added to reduce the risk of part delamination and damage onto the part. Combining these additional features reduces warping and avoids part and/or build platform damage.

For more information, see the Build Platform Adhesion guide.

PEI Build Sheet Single-Use (Multiple Uses With Nano Polymer Adhesive)

We recommend two methods of printing on the PEI build sheet:

  1. Using the PEI build sheet only one time. The PEI build sheet offers the best adhesion to ULTEM™ AM9085F. Part removal after printing is often difficult to manage as the part and/or the PEI build sheet may get damaged as shown below. The part and the PEI build sheet may fuse, ultimately requiring post-processing to clean the part.

Damaged PEI Build Sheet

A sacrificial temperature gradient raft may be used to reduce bed adhesion, protecting the part and/or build platform. The first layer can be printed at a slightly lower extrusion temperature, then gradually increased in the raft until it meets the bottom of the part’s surface. The temperature gradient must be small and occurs over many layers to reduce print warpage by reducing the stress gradient in the part. Fine-tuning the temperature gradient and printing speed will make the part release from the raft easily. Printing the raft this way will compensate for toolhead expansion. Increasing/decreasing thick and thin raft layers will affect raft ease of removal.

For example, the table below illustrates a possible temperature gradient using a raft with 1 thick base and 2 thin top layers to reduce first layer adhesion but adequate interlayer adhesion:

Layer Number Extrusion Temperature Raft Layer Type
1 360ºC Base - Thick
2 365ºC Top - Thin
3 370ºC Top - Thin
4 370ºC First Layer of Part
5 380ºC Second Layer of Part

If the thin raft is hard to remove from the bottom layer of the part, lower the extrusion temperature and/or increase the Separation Distance to decrease the adhesion between the two interfaces. Be cautious as the internal stresses within the part may accumulate enough to cause warping if you try to reduce the adhesion between the raft and the bottom layer of the part too much.

Alternatively, you can take advantage of the strong first layer adhesion. Large prints with severe warp-prone geometries may be ideal to print just on the PEI build sheet as a single-use application. Doing so will ensure that the part does not warp after many hours of printing. The trade-off of a successful print would be the single-use application of the PEI build sheet. Part removal may be difficult and will require post-processing, but warping may not be a major problem during printing.

  1. Using the PEI build sheet multiple times but with the use of Nano Polymer Adhesive as a release agent. The use of Nano Polymer Adhesive helps facilitate part removal without damaging the part and/or PEI build sheet A brim is recommended to reduce warping at warp-prone geometries due to the decreased first layer adhesion.

Depending on the sheet integrity, the PEI build sheet can be reused many times depending on the impact of breakage or thermal deformation. Wipe down the PEI build sheet with isopropanol before use. The first layer must be thick and can be printed at a lower extrusion temperature if part removal is difficult to complete without damage. The extrusion temperature can then be gradually increased in the part to optimal extrusion temperatures.

First Layer Adhesion

The first layer must be thick and can be printed at overall extrusion or slightly elevated extrusion temperatures to increase first layer adhesion. If needed, the extrusion temperature can be gradually increased in the part for optimal extrusions.

Start with a First Layer Height and First Layer Width of 100-120% for both and adjust until desired bed adhesion is achieved.

First Layer Extrusion Temperature First Layer Speed
395ºC 20 mm/s

For warp-prone geometries, anchors may be added onto localized regions of the part.

For more information, see the Build Platform Adhesion guide.


Dual Extrusion and Support

SABIC AMS31F is a compatible breakaway support material for ULTEM™ AM9085F. Dual tool printing with ULTEM™ AM9085F and AMS31F requires fine-tuning for optimal printing. For more information about printing with this support material, see the SABIC AMS31F guide.

The adhesion between ULTEM™ AM9085F and AMS31F is poor. Slower printing speeds and/or higher extrusion temperatures may be needed to increase the adhesion between the model material and support structures. If not, delamination between the two interfaces may cause print failure.

Extended periods while idling may cause material degradation due to the required high extrusion temperatures. Degraded ULTEM™ AM9085 extrusions may be light-brown in color as shown below.

Degraded Material

Between each toolhead change, a dwell time of at least 2 seconds may be needed after each purge before wiping in the Tool Change Script. The additional time allows for the purged material to cool down (preventing it from sticking to toolhead and flicking more easily) and fall after being hit by the flat brush and blade wiper assembly. Material accumulation from the purged material curling and sticking to the toolhead is then reduced, as well as with the addition of a wiping sequence.

Wiping Sequence

Below is a Tool Change Script example that combines wipe sequences, dwell periods, and M104 & M109 commands to clean the toolheads:

{IF OLDTOOL=0} T1 ; AMS31F, support toolhead
{IF OLDTOOL=0} M104 T0 S350 ;reduce T0 temperature
{IF OLDTOOL=0} M109 T1 S385 ;set T1 temperature and wait
{IF OLDTOOL=0} G91 ;relative mode
{IF OLDTOOL=0} G1 E5 F30 ;extrude 5 slow
{IF OLDTOOL=0} G4 S2 ;dwell 2 second
{IF OLDTOOL=0} G1 X60 F10000 ;move T1 tool head to wipe
{IF OLDTOOL=0} G1 X-30 F10000 ;move T1 tool head to wipe
{IF OLDTOOL=0} G1 X30 F10000 ;move T1 tool head to wipe
{IF OLDTOOL=0} G1 X-30 F10000 ;move T1 tool head to wipe
{IF OLDTOOL=0} G1 X30 F10000 ;move T1 tool head to wipe
{IF OLDTOOL=0} G1 X-60 F10000 ;move T1 tool head to wipe
{IF OLDTOOL=0} G1 E5 F30 ;extrude 5 slow
{IF OLDTOOL=0} G4 S2 ;dwell 2 second 
{IF OLDTOOL=0} G92 E0 ;reset extruder
{IF OLDTOOL=0} G90 ;absolute mode

{IF OLDTOOL=1} T0 ; ULTEM™ AM9085F, main toolhead
{IF OLDTOOL=1} M104 T1 S355 ;reduce T1 temperature
{IF OLDTOOL=1} M109 T0 S385 ;set T0 temperature and wait
{IF OLDTOOL=1} G91 ;relative mode
{IF OLDTOOL=1} G1 E5 F30 ;extrude 5 slow
{IF OLDTOOL=1} G4 S2 ;dwell 2 second
{IF OLDTOOL=1} G1 X60 F10000 ;move T0 tool head to wipe
{IF OLDTOOL=1} G1 X-30 F10000 ;move T0 tool head to wipe
{IF OLDTOOL=1} G1 X30 F10000 ;move T0 tool head to wipe
{IF OLDTOOL=1} G1 X-30 F10000 ;move T0 tool head to wipe
{IF OLDTOOL=1} G1 X30 F10000 ;move T0 tool head to wipe
{IF OLDTOOL=1} G1 X-60 F10000 ;move T0 tool head to wipe
{IF OLDTOOL=1} G1 E5 F30 ;extrude 5 slow
{IF OLDTOOL=1} G4 S2 ;dwell 2 second 
{IF OLDTOOL=1} G92 E0 ;reset extruder
{IF OLDTOOL=1} G90 ;absolute mode

Be cautious when using M104 as lowering the ULTEM™ AM9085F extrusion temperature while idle may be problematic. The Material Buildup at Nozzle from printing may not soften enough in time, potentially crashing into the part. By using M109, the toolhead will wait until it reaches the desired extrusion temperature before printing. As the toolhead heats up, the interface between the toolhead and accumulated material may be molten enough for ease of removal with a wiping sequence. The Tool Change Script must be optimized based on the processing parameters (extrusion and environment temperature) and geometry (timer per toolhead path) to efficiently clean the toolheads.

For more information, see the Using Supports and Support Materials and Dual Extrusion guides.

Sample Slicer Profiles with AMS31F Support

Dual Extruder with AMS31F Support, 0.4mm nozzle

Dual Extruder with AMS31F Support, 0.6mm nozzle

Post-Processing

Allow all machine components to reach room temperature before proceeding further. Failure to allow components to cool down will result in thermal injury (burns) to personnel.

High-Temperature Build Plate

ULTEM™ AM9085F parts may not separate easily from the High-Temperature Build Plate. Damage to the part and/or the build platform may occur during part removal. The use of a spatula can facilitate part removal if needed.


Shrinkage, deformation, and warpage due to thermal shock may occur from removing the part before letting the machine cool. Instructions for removing the part from the build platform and additional support material can be found on the Build Platform Adhesion and Using Supports and Support Materials guides.

High-Temperature Build Plate

ULTEM™ AM9085F parts may not separate easily from the High-Temperature Build Plate. Damage to the part and/or the build platform may occur during part removal. The use of a spatula can facilitate part removal if needed.


Shrinkage, deformation, and warpage due to thermal shock may occur from removing the part before letting the machine cool. Instructions for removing the part from the build platform and additional support material can be found on the Build Platform Adhesion and Using Supports and Support Materials guides.

PEI Build Sheet Single-Use (Multiple Uses With Nano Polymer Adhesive)

ULTEM™ AM9085F parts may not separate easily from the PEI build sheet. Part removal may be easier if Nano Polymer Adhesive is used as a release agent between the interface of the part and the PEI build sheet. The use of a spatula can facilitate part removal if needed.

Avoid removing prints while the PEI build sheet is still hot. If not cooled, permanent deformation of the PEI build sheet may occur when removing a large part with a lot of contact area.


Shrinkage, deformation, and warpage due to thermal shock may occur from removing the part before letting the machine cool. Instructions for removing the part from the build platform and additional support material can be found on the Build Platform Adhesion and Using Supports and Support Materials guides.


Troubleshooting

Nozzle Material Build Up

The accumulation of ULTEM™ AM9085F on the nozzle of the toolhead is common when printing with this material due to its adhesive and viscoelastic properties as shown below. Material accumulation may cause undesired print defects on the print such as stringing or burnt material. Toolhead collisions and fractures may also occur, especially during dual toolhead prints if the accumulated material falls.

Material Accumulation

Each layer will require a wiping script for the nozzle using the flat brush and blade wiper assembly. The Layer Change Script tab under the Scripts section can be used to add a wiping sequence to clean the nozzle before each layer. To ensure that the accumulated material gets removed, the nozzle must remain at extrusion temperatures.

For example, a single extrusion print may use a similar wiping script as shown below:

G91 ;relative mode
G1 X60 F10000 ;move T0 tool head to wipe
G1 X-30 F10000 ;move T0 tool head to wipe
G1 X30 F10000 ;move T0 tool head to wipe
G1 X-30 F10000 ;move T0 tool head to wipe
G1 X30 F10000 ;move T0 tool head to wipe
G1 X-60 F10000 ;move T0 tool head to wipe
G90 ;absolute mode

The purge and dwell period sequence as shown in the Dual Extrusion and Support may not be needed when printing with a single toolhead. We can avoid purged material curling and accumulate on the toolhead by only performing wiping sequences.

Rough Texture

Drying of ULTEM™ AM9085F is critical for optimal printing performance, but maintaining dryness is also difficult. Hydrated filament may produce undesired rough texture as shown below.

Rough Texture

The part initially prints with a smooth texture, but eventually becomes rough. The material was initially dried, but dryness was not properly maintained throughout the print. Thus, the material quickly hydrated and the print was affected.

Follow the drying procedure in the above Moisture Control section.

Stringing

Drying of ULTEM™ AM9085F is critical for optimal printing performance, but maintaining dryness is also difficult. Hydrated filament may produce stringing as shown below.

Stringing

Stringing may occur if material accumulates at the nozzle and drags along the print as explained in the above Material Buildup at Nozzle section. However, if stringing and a rough texture occur during the print, the material is most likely hydrated.

Follow the drying procedure in the above Moisture Control section.

If stringing/oozing occurs even when properly dried and fed from a low humidity environment, slightly increase the Retraction Distance and/or the Retraction Speed but try not to adjust the Coasting Distance. Large Coasting Distance values become very noticeable on the seams of parts.

Large Seam Holes

Large holes may appear at the end of each extrusion if the Ooze Control settings have not been optimized. Avoid using large Coasting Distance values in the Ooze Control section due to its viscoelastic nature. Large Coasting Distance values may cause large visible seams in the part compared to other thermoplastics as shown below. ULTEM™ AM9085F benefits more from larger Retraction Distance and Retraction Speed values for Ooze Control behavior.

Stringing

Discoloration

A color change may occur on your part if the process parameters have been changed throughout the part. While the discoloration has minimal effect on the mechanical and thermal properties, we still recommend using a single-speed and temperature throughout the entire print and for all features to avoid that if possible. ULTEM™ AM9085F is a bit more susceptible to visual discrepancies when process parameters are not constant compared to other thermoplastics. As shown below, bridging and overhangs were improved by decreasing the layer height at a localized region. However, the decreased layer height section became darker in color.

Discoloration

Avoid adjusting process parameters such as flow rate and temperature throughout a model if the discoloration is undesired. Keep those variables constant as much as possible to maintain an even surface finish. However, critical areas that benefit from process changes may act as stress concentrations if not compensated for.

Last modified: January 24, 2022