Flame retardant resin, also known as fire-resistant resin, is a type of polymer material specifically formulated to resist ignition and inhibit the spread of flames. The purpose of flame retardant resins is to reduce flammability and slow down the burning rate of the materials they are incorporated into.
Different types of flame retardant additives are used in resin formulations, including halogenated compounds, phosphorus-based compounds, nitrogen-based compounds, and mineral fillers. They release flame-inhibiting gases, form a protective char layer, or interrupt the combustion process. The specific mechanism varies depending on the flame retardant additives used and the resin matrix.
Advantages and disadvantages of each type come down to fire performance, environmental impact, and processing requirements.
Phosphorus-based flame retardants, such as phosphates or phosphonates, are commonly used in flame retardant resins. They can work by forming a protective char layer on the material’s surface, which acts as a barrier to heat and oxygen, thus slowing down the combustion process.
Nitrogen-based flame retardants, like melamine or melamine derivatives, release inert gases with heat exposure, diluting the oxygen concentration and suppressing the flame.
Mineral fillers, such as aluminum hydroxide or magnesium hydroxide, work by absorbing heat during combustion and releasing water vapor, which helps cool down the material and prevent the spread of flames.
- Halogenated flame retardants, such as brominated or chlorinated compounds, have traditionally been widely used due to their effectiveness. However, they have raised concerns about their potential toxicity and environmental persistence. As a result, there has been a shift towards developing more environmentally friendly alternatives- Inquire about Formlab’s new Halogen-free Flame Retardant Resin.
It’s important to note that the choice of flame retardant resin depends on the specific requirements of the application, including fire safety regulations, environmental considerations, and performance criteria. It is commonly used in various applications for industries such as aerospace, automotive, electronics, construction materials, electrical and electronic devices, automotive components, textiles, and more. Different industries and regions may have specific standards and regulations governing the use of flame retardant materials.
Flame Resistant Material and Additive Manufacturing
Formlabs adds to their extensive Resin Library with new Flame Resistant resin. The favorable flame, smoke, and toxicity (FST) ratings are crucial in applications where fire safety is a concern. These ratings imply that FR Resin performs well when exposed to fire, produces minimal smoke, and exhibits low toxicity, making it suitable for use in environments to mitigate fire risk where people or sensitive equipment may be affected.
With that comes new opportunities with additive manufacturing for industries such as aerospace, electrical and airplane, automobile, and railway interior parts, protective and internal consumer electronics components, and custom jigs, fixtures, and replacement parts for industrial environments.
Product Description: Flame Retardant (FR)Resin is a self-extinguishing, halogen-free, certified UL94V-0SLA material with favorable flame, smoke, and toxicity (FST) ratings. It offers a 2.9 GPa tensile modulus (elasticity) and a heat deflection temperature (HDT) of 112 °C @ 0.45 MPa (pressure).
In the context of 3D printing, “halogen-free” refers to materials or resins that do not contain halogen elements such as chlorine (Cl), bromine (Br), or fluorine (F). Halogen-free formulations are sought after for a variety of reasons, including environmental concerns, health and safety considerations, and regulatory requirements.
When exposed to high temperatures, halogen-based compounds can release corrosive and toxic gases, which can be harmful to human health and the environment. By eliminating halogens, Formlabs FR Resin contributes to better fire safety and reduced toxicity.
The ability to 3D print with Formlabs Flame Resistant Resin offers several advantages-
First, 3D printing allows for complex geometries and intricate designs that may be difficult or impossible to achieve with traditional manufacturing methods.
Second, the high part quality ensures that the printed components meet the required specifications and have reliable mechanical properties.
Lastly, the high creep resistance of FR Resin and heat resistance ensures that the printed parts maintain their dimensional stability and structural integrity even under prolonged mechanical stress or elevated temperatures.
Overall, FR Resin is a versatile and reliable material for 3D printing flame-retardant parts, and provides a combination of fire safety, heat resistance, and processability, making it a suitable choice for manufacturing parts that need to withstand challenging environments while allowing for additional post-fabrication operations and optional post-processing steps.
When working with flame retardant resins for 3D printing, it’s crucial to follow Formlabs guidelines, including printing parameters, post-processing requirements, and safety precautions. Additionally, it may be necessary to comply with industry-specific fire safety standards and regulations for the intended application of the 3D-printed parts.
Always reference the Safety Data Sheet in accordance to OSHA Hazard Communication Standard, 29 CFR 1910.1200 as of March 2023.
Formlabs Flame Resistant Certifications
Flame Retardant Resin is UL94 V-0 and FAR25.853 certified.
Formlabs is UL 94 V-0 certified and has test data on FAR 25.853 Appendix F, Part I (a) (1) (ii)12 seconds Vertical Burn as well as smoke (ASTM E662) and toxicity tests (BSS 7229).
Flame Retardant (FR) Resin’s self-extinguishing properties and UL94 V-0 certification indicate that it has undergone rigorous testing and meets high safety standards. The UL 94 V-0 rating is achieved for a minimum wall thickness of 3mm.
The following table contains additional correspondence between FAR, Airbus, and Boeing standards.
Formlabs Printer Compatibility with FR Resins
New Formlabs Flame Retardant Resins are compatible with the following printers:
It is also compatible with the listed Formlabs Resin Tanks:
- Form 3/3B Resin Tank V1
- Form 3/3B Resin Tank V2
- Form 3/3B Resin Tank V2.1
- Form 3L/3BL Resin Tank V1
- Form 3L/3BL Resin Tank V2
Use Formlabs Flame Retardant Resins with the build platforms:
- Form 3 Build Platform
- Form 3 Build Platform 2
- Form 3L Build Platform
- Form 3L Build Platform 2
Note: Print settings for this material may not be available yet on Form 3L and Form 3BL printers. Talk to an EAC expert for additional support.
Special Workflow Considerations
Formlabs experts highly recommend shaking the resin cartridges vigorously while rotating occasionally for at least 2 minutes before starting your first print. Failure to do so may affect the flame retardancy properties of your printed parts. If it has been more than 2 weeks since your last print, shake the cartridge again for 2 min and stir the resin in the tank before printing.
The resin is viscous, so allowing it to automatically dispense into a new tank for the first time before printing will result in a printer timeout error. Instead, please follow the instructions for manually pre-filling the resin tank before printing.
Due to the viscosity of Flame Retardant Resin, Formlabs recommends priming a new resin tank to reduce print time and avoid tank fill error messages.
Priming a Form 3: Unscrew the vent cap at the top of the cartridge and manually pour around 350 ml of the resin into the new resin tank bank.
Priming a Form 3L: Unscrew the vent cap at the top of the cartridge and manually pour the contents of one full cartridge of resin into the new resin tank.
Recommended Finishing Techniques for FR Resin
The parts made from the flame-retardant resin can undergo optional post-processing steps like painting or electroplating. This offers flexibility in terms of the final appearance or functionality of the parts, as they can be customized to meet specific requirements.
Sanding or polishing to create a smoother surface by removing scratch marks can be done after the post-cure. Sanding with 600-grit sandpaper is sufficient to remove support nubs. Using a lower grit may additionally abrade the surface. For a smoother finish, higher-grit sandpaper up to 3000 grit can be used. Alternatively, polishing wheels combined with a rotary tool can be used for a quicker and even surface finish.
It is important to note that priming or polishing the surface of parts printed with Flame Retardant Resin with mineral oil or other flammable lubricants may invalidate the UL flammability rating.
Additionally, small negative features may be difficult to fully clean due to the resin’s high viscosity. Make sure to clean your parts thoroughly before post-curing! Consider using pressurized air for better cleaning.
Want to see in person how the parts self-extinguish? Visit us at our CXC in Minneapolis to get hands-on with multiple printed samples.
Creo Parametric is a powerful computer-aided design (CAD) software that has been helping engineers and designers bring their ideas to life for over 30 years. With the release of Creo 10, users can expect a number of new features and improvements in productivity, designs, and more!
What’s New in Creo 10
Discover Creo 10’s newest improvements and enhancements.
User Interface Enhancements
PTC has made a big splash with the release of Creo 10, including an enhanced user interface.
Split & Trim Tool
Use this tool to quickly and easily split or trim a model, making it painless to work with and modify your model. Additionally, the ability to propagate appearances and references during Boolean operations makes it easier to maintain consistency throughout a project.
Stretch Tool in Warp
Utilize the Stretch Tool to select defined references to stretch models, making it easier to create complex shapes and designs. Users now have the ability to select Datum Planes, Points, Axis, Coordinate Systems, Surfaces, Curves, Facets, and more.
Freestyle and Style Tools
Both tools are enhanced with Rotational Symmetry and Smooth Normal Connection, making it easier to create organic shapes and designs. These tools are perfect for designers who want to create complex, freeform shapes that are difficult to create with traditional CAD tools.
The Model Tree
Creo’s Model Tree tool has been improved, making it easier to restructure and reorder assemblies to reduce confusion and improve the management of complex projects.
New Pattern Parameters
Finally, the pattern capability in Creo 10 enables users to drive pattern member count for nested patterns. Create complex patterns quickly and easily, saving you time and improving overall productivity.
Optimize Your Design
Take your design process to the next level with Creo 10’s newest additions.
Composites
Designing composite materials has never been easier with the new features in Creo. The software now offers a broad set of functionalities for defining ply layup, ply sections, transitions, and ply order. This allows you to create a resulting solid geometry and inner mold line (IML) quilt that meets your exact specifications.
In addition, Creo’s new Splicing and Darting operations, makes it easier to create complex composite designs. Once a design is complete, you can automatically generate a complete plybook documentation of the final layup sequence.
With new composite design features in Creo 10, you can easily create high-quality composite materials that meet your needs and specifications. Whether you’re designing for aerospace, automotive, or any other industry, Creo’s composite design tools can help you create the perfect product.
Electrification
Creo 10 presents new features that streamline and enhance the process of designing for electrification.
Split/Merge Harness Tool for Cabling
One of the most significant additions is the Split/Merge Harness Tool for Cabling. This tool allows users to split a harness into two separate pieces and later merge them back together. This feature is particularly useful when working on complex designs that require multiple harnesses.
Simultaneous Harness Design
Another key feature of Creo 10 is the ability for multiple users to work on the same harness design simultaneously. This collaborative design approach saves time and ensures that everyone is on the same page. The application-centric tree is another useful addition, which provides three different views, including Cables, Bundles, and Connectivity, to make it easier to navigate.
New ECAD Capabilities
Creo 10 includes new ECAD capabilities, such as paste masks and hole parameters. These features make it easier to create accurate designs that meet the specific needs of each project with greater precision and accuracy.
Ergonomics
Creo 10 optimizes and simplifies the design process for ergonomics.
The Visual Field
Perform Reflection Analysis to analyze the reflective properties of objects in the environment and how they impact the user’s visual experience. The reflective object orientation can be controlled by adding a rotation value around one or two axes, giving you greater control over the design process.
Creo Manikin
Another key feature of Creo 10 is the Manikin, which now support multiple reach envelopes, including the index and middle finger, thumb, and center of the palm. Creo Manikin allows designers to create more accurate models of human movement and reach, making it easier to design products that are comfortable and easy to use. Additionally, the Manikin libraries are now stored as inseparable assemblies to provide better management and user access.
Enhancing Model-Based Definition and Implementing the Digital Thread
Creo 10 introduces significant updates to Model-Based Definition (MBD) and Digital Thread capabilities, to better create, manage and access real-time product data across the entire product lifecycle.
Enhanced 3D Model Annotations
One of the most significant additions is the ability for users to relate symbols or surface finishes to other annotations in the 3D model. This feature allows designers to create more accurate and detailed models, making it easier to communicate design intent to other stakeholders and downstream activities.
Creo 10 adds the ability for annotations to inherit their annotation plane from the parent during placement. This feature ensures that annotations are placed correctly and in the right location, saving time and improving accuracy. Additionally, any movement of the related parent annotation would also be applied to related symbols, behaving as a group when being assigned to other combination states.
GD&T Advisor Updates
Creo 10 includes improvements to GD&T semantic behaviors, including general profile tolerances and enhanced compliance with detailing standards. These changes make it easier for designers to create accurate and detailed models, ensuring that the design intent is communicated effectively throughout the product lifecycle.
Furthermore, any changes made to GD&T annotations will automatically update the corresponding semantic references of general profile tolerance. Additionally, Creo 10 now supports straightness and profile of Line Geometrical Characteristics for ISO GPS models. Create more accurate and detailed models, ensuring that the design intent is communicated effectively.
Advanced Simulation and Optimization Capabilities
Creo 10 presents a range of new features that enhance and streamline the process of simulation and optimization.
Support for Non-Linear Materials
This includes Neo-Hookean hyperplasticity, linear orthotropic elasticity, and bi-linear plasticity.
Combined Thermal & Structural Analysis
Another key feature is the support for combined thermal and structural analysis. Enable your designers to easily simulate how a product will perform under both thermal and mechanical loads, ensuring that the design is optimized for real-world conditions.
Support for non-linear contact, including new contact types such as frictional and rough, helps to create more accurate simulations of real-world contact.
Expanded Contact Simulation Options
PTC included improvements to Creo Simulation Live, to improve result options for fluids and structures. Furthermore, Creo Flow Analysis and Creo Simulate now have better Animation and Multi-Body Support.
Rotational Symmetry
Allows designers to create more accurate simulations of rotational components.
Point Mass & Remote Loads
Finally, Creo 10 introduces the ability to add Point Mass and Remote Loads to create more accurate simulations of real-world loads.
Creo 10: Additive and Subtractive Manufacturing
With Creo 10’s latest features, manufacturing processes are now more efficient and effortless. One of the most significant additions is the support for additive manufacturing.
New Lattice Types
This enables your designers to create new beam-based lattice types, including rhombic, rhombic+diamond, dodecahedron, and elongated dodecahedron. For formula-driven lattices, Creo 10 supports simulation-based variable wall thickness and highly efficient I-graph-wrapped (IWP) lattice cell. Additionally, Creo 10 supports Auxetic Cells Structures for 3D printing. Auxetic Cell Lattices produce geometry that exhibit a negative Poisson ratio.
High-Speed Milling
High-Speed Milling supports barrel tools for both wall and floor 5-axis finish, reducing tool path time and improving surface finish quality. Additional control for CUTCOM and clearance has been added to Area Turning, making it easier to create accurate and efficient toolpaths for subtractive manufacturing processes.
Get started with Creo 10 Today
Creo 10 is an exciting new release from PTC that brings a plethora of new features to the design table. Whether you’re a designer or an engineer, Creo 10 is a game-changing tool that will help you create complex shapes and designs, manage projects, and improve productivity for more innovative products.
Curious to see how Creo 10’s features compare to other versions of Creo? Check out how Creo is continually enhancing its tools to provide you with the most up to date features for your design process.
To learn more about how Creo 10 can positively impact your business or to experience the new features first-hand, book a free demo now.
EAC and INTAMSYS are partnering to expand 3D printing solutions for the Midwest
EAC Product Development Solutions, a Premier PTC partner, has recently entered into a strategic alliance with INTAMSYS to amplify their concentration and assistance towards Additive Manufacturing concerning product development.
Who is INTAMSYS?
Specializing in high-performance materials, INTAMSYS is a world-renowned expert in advanced solutions for 3D printing and industrial additive manufacturing.
INTAMSYS offers advanced 3D-printing solutions that are fine-tuned to cater to the specific needs of various industries and organizations, with the support of its partner network.
Offering a diverse array of 3D printing hardware, INTAMSYS effectively meets the needs of various industries, including but not limited to Aerospace, Automotive, Manufacturing, Consumer Goods, Healthcare, and Research.
INTAMSYS operates across multiple locations. They are headquartered in Shanghai (China) with regional offices in Stuttgart (Germany) and Minneapolis (Minnesota), where they extend their services to offer sales, operations, and support for their cutting-edge technology.
“We are very excited to be partnering with EAC Product Development Solutions”, says INTAMSYS CEO Charles Han. “EAC Product Development Solutions have a proven track record with various product development software offerings that strongly reside adjacent to our solutions. We believe this is the beginning of a strong partnership as they further dive into additive manufacturing with INTAMSYS. Plus, it doesn’t hurt that they are right down the street from our Minnesota office.”
EAC’s Industry Role
EAC Product Development Solutions, a predominant player in the product development industry, prioritizes staying ahead of the curve by providing top-of-the-line technology solutions to clients while also being responsive to market trends and customer demands. Teaming up with INTAMSYS enables EAC to enhance their market offerings, addressing additional business challenges encountered by their customers.
EAC Product Development Solutions (EAC) provides innovative solutions that transform the way companies design, manufacture, connect to, and service their products. The organizations’ primary objective is to improve and optimize product development systems, with the ultimate goal to help clients succeed in the marketplace.
EAC is renowned for their unparalleled expertise in product development, systems, architecture and innovative solutions, particularly in the areas of Product Lifecycle Management (PLM), the Internet of Things (IoT) and Augmented Reality (AR).
“We help businesses and organizations in various industries change the way they design, manufacture and service their products by implementing a two phased digital thread strategy. We first optimize information flow and then transform business processes to enable companies to gain a competitive advantage with faster time to market, less waste, increased innovation, lower costs, and higher profits.” Thane Hathaway
EAC’s Partnership with INTAMSYS
Prior to the partnership, INTAMSYS aimed to form a strong alliance with a technology solutions provider in the Midwest region, renowned for exceptional customer service. After considering various options, INTAMSYS determined that partnering with EAC would result in an unmatched collaboration that would surpass any other potential partnership.
With the ability to leverage EAC’s broad portfolio of technology, services, and solutions; INSTAMSYS plans to enhance offerings revolving around anything from prototypes to functional real-world end-use parts that encompass real material properties for production, manufacturing, and industrial applications.
Expanding territory coverage and market presence, the partnership greatly aids both organizations, as well as their clientele, providing each to benefit from the proficiencies of one another.
