Delivering on the promise

of Additive Manufacturing
SPECIALTY
POLYMERS
 In the last century, communications, imaging, architecture
and engineering have all undergone their own digital
revolutions. Now it’s the turn of manufacturing operations,
thanks to something that in the near future could disrupt
the whole manufacturing system: Additive Manufacturing.
It is evident that Additive Manufacturing, represents a
paradigm shift that brings digital flexibility and efficiency
to the design and manufacturing of products: it is
developing fast, and market expectations are growing.
In 2017 the Additive Manufacturing market is worth
$7.3 billion. In 2025 its market value is estimated to be
worth at least $100 billion.
We’re creating a series of unique visionary partnerships
to connect the pioneering forces operating in the world of
Additive Manufacturing today. A dynamic ecosystem
of passionate people to help pioneering companies
explore new synergies to find the best material,
process and design.
Why?
Because we have one mission:
to take Additive Manufacturing to the next level.

But even if the goal is set, to reach it won’t be so easy:

the quality and selection of 3D printing materials still
needs to be continually optimized, together with printing
processes and software design.

Today in Solvay, thanks to our unique offer of Specialty

Polymers, and our spirit of innovation, we aim to provide
solutions that will enable 3D-printed applications to take
on the challenges of the world’s most demanding
industries, such as Healthcare where we are providing
new medical grade filaments that will enable access
to a new range of limited exposure applications.

But we won’t do this alone.

2 \ Delivering on the promise of Additive Manufacturing

Table of contents

1. Additive Manufacturing is developing fast…

2. … but not fast enough
3. Taking Additive Manufacturing to the next level
4. Superior solutions for the most demanding industries
5. Solvay AM-ready materials key properties
6. Our new medical grade AM-ready filaments
7. How to use Solvay AM-ready materials
8. How to order online

Delivering on the promise of Additive Manufacturing /3

 Additive Manufacturing is developing fast…
Additive Manufacturing (AM) is challenging the mindset of manufacturers to change from their traditional production
processes because it has the potential to be significantly more cost effective, increase responsiveness and result
in improved product value.

Reduction in tooling Agile manufacturing operations

Unlike injection molding and metal casting, AM Manufacturing without tools gives the benefit
reduces the need for tooling – benefits: of being able to change product mix at short notice:

• Costs and lead-times decline • Parts can be made to order

• Quicker time to market • Quicker reaction to changing market conditions
• Elimination of production delays due to damaged • Modification of production rates to match demand
or worn tools

Part consolidation Decentralized manufacturing

AM enabled part consolidation method promises: When a single AM machine can build complex parts:

• Possibility to build complex shapes
• Production of many parts into one or fewer parts
• More design freedom
• Lower cost and time to set up a production facility
• Distribution of manufacturing on a more
local basis
• Decrease in component and final product
transportation (shipping)

Inventory reduction Sustainability and environmental

Just-in-time operations mean: impact
• Fewer parts held in inventory AM could represent the missing link to foster
the spread of a circular economy, through:
• Reduction in onsite storage and off-site
warehousing • Reduced waste generation
• Reduction in overheads associated with • Products kept in longer usage
documentation, inspection, planning and control • Reduced emissions (both during production
• and usage of the final products)

4 \ Delivering on the promise of Additive Manufacturing

…but not fast enough.
3D printing can deliver fully functional prototypes, as well as cost-efficient single to small volume applications, much faster
than traditional manufacturing.

However Additive Manufacturing using high-performance polymeric materials remains a challenge.

Limited materials choice:

there are over 70,000 materials for traditional manufacturing. Only a few hundred
has been developed for AM and almost none of them are high-performance materials.

AM product quality:
challenge to reach performance properties (Z-axis strength) & surface finish of injection molded
or extruded parts.

Repeatability:
the same settings can result in differences in the production of the same products. This is attributable
primarily to process parameters, which are numerous and have to be tightly controlled and monitored.
This complexity can be intimidating for companies waiting on the sidelines.

The Skill Gap:

success requires a well-trained, capable and skilled workforce. Without this workforce, companies may lag
or fail in their attempts to utilize Additive Manufacturing processes. Finding this workforce is difficult. Education
in Additive Manufacturing design, processes, machines and technology is necessary to enable the transition.

Delivering on the promise of Additive Manufacturing /5

 Taking Additive Manufacturing to the next level
Leading the change…
“There are no limits to what science can explore”
Ernest Solvay

For more than 150 years Solvay has distinguished itself

for its innovating spirit. That is why Solvay today is a global
leader in high performance polymers positioned
at the leading-edge of the industry.

A unique solutions portfolio of 35 Specialty Polymer

brands available in over 1,500 high-performance
formulations in the categories of aromatics,
fluoropolymers, barrier polymers and performance
compounds. Solutions designed to meet the property
requirements of demanding industries such as
Automotive, Aerospace, Smart Devices, Healthcare
and Energy Production.

What if we were to take our leadership and expertise into

the Additive Manufacturing market? It started
as a question, it became an opportunity to be seized.

Today we offer high-performance AM-ready solutions

that will enable previously impossible applications and
designs: we started with the introduction of tailor-made
AM-ready filaments and powders based on our highest
performing Specialty Polymers, KetaSpire® PEEK,
NovaSpire™ PEKK, Radel® PPSU, Ryton® PPS and Solef®
PVDF.

PEEK PPSU PVDF And More…

• Offering better printability
• Allowing better fusion
of layers
• Enabling high part density
• Offering exceptional
part strength, even
in the z-axis
• Allowing better fusion of
layers
• Enabling part transparency
• Offering high elongation
• Providing highest toughness
• Very high purity • Direct access
• Exceptional chemical to filament from leading
resistance material supplier
• Low friction • First generation of materials
to be followed by new
• Print profile available
complementary products
for Ultimaker
in the coming months
and years
• First AM ready materials
from the broadest portfolio
of High Performance
Materials in the industry,
with many more to follow

6 \ Delivering on the promise of Additive Manufacturing

… through an open and inclusive ecosystem.
The launch of PEEK, PPSU and PVDF AM-ready materials is just the beginning: we will continue to evolve as we proceed
to increase our range to include more high-performance materials, but AM is not just about high-performance materials.

To take AM to the next level there’s only one way: optimize materials, design and processes.

That’s why we’re building an ecosystem of industry leaders and passionate people.

Printer Manufacturers

Material Developers Service Platforms

Software, Modelling & Processing

Design Assistance Providers Experts & Print Shops

Disruptive Printing Technologies

Delivering on the promise of Additive Manufacturing /7

 Superior solutions for the most demanding industries
Based on three of our best known, high‐performing
polymers KetaSpire® PEEK, Radel® PPSU and Solef®
PVDF, our AM-ready filaments signal the important
convergence between Additive Manufacturing and
Specialty Polymer technology. They opened the pathway
to developing exactly what is needed to deliver on the
promise of high‐end 3D printing.
• Ketaspire® polyetheretherketone (PEEK) polymer
is available as a neat PEEK product and a 10-percent
carbon fiber-reinforced grade (Ketaspire® CF PEEK
AM). Both PEEK filaments are designed to allow
excellent fusion of printed layers, enable high part
density and deliver exceptional part strength, including
in the z‐axis.
• We offer filaments based on Radel®
polyphenylsulfone (PPSU). Also formulated to allow
excellent fusion of layers, this high‐performance PPSU
material offers high transparency, excellent elongation
and superior toughness for 3D‐printed parts.
But this is just the beginning of our mission, as shown
by the recent introduction of the new medical grades
of KetaSpire® PEEK AM and Radel® PPSU AM and the
upcoming launch of our brand new AM‐ready powder
based on our NovaSpire™ polyetherketoneketone (PEKK)
polymer, which will target AM applications in Aerospace
and Healthcare.
8 \ Delivering on the promise of Additive Manufacturing
Our AM-ready filaments have been developed to maintain
the same high-performance properties of their original
injection molded materials:
KetaSpire® PEEK AM Filament and Powder
Provides a unique combination of properties that will
constantly perform at temperatures of up to 240 °C.
Added to its exceptional chemical resilience, KetaSpire®
PEEK can be used to replace metals in critical enduse
environments such as Oil & Gas, Aerospace and
Automotive.
Radel® PPSU AM Filament
Among our sulfone polymers it delivers to the most
elevated levels, with a superiority in both toughness
and impact strength as well as proven outperformance
in chemical resistance for both PSU and PEI destined
to Healthcare, Smart Devices and Energy Storage
applications.
Solef® PVDF AM Filament
Thanks to its intrinsic very high purity it provides long
term performance up to 120 °C, exceptional chemical
resistance and outstanding UV, weathering and oxidation
resistance. These features make it particularly suited for
Chemical Processing Industry, Semiconductor Industry,
and Oil & Gas applications.
NovaSpireTM PEKK AM Powder
With its faultless flame, smoke and toxicity performance
as well as its optimum resistance to a wide range of fluid
environments, it is the perfect choice for Aircraft, Space
and Transportation components.
 Solvay AM-ready materials key properties
We know that even the smallest detail can be so important when designing high-end applications. We have therefore
prepared a comparison of the key mechanical performances of our Specialty Polymer AM-ready filaments.

Tensile modulus Tensile modulus Tensile modulus

100% 100% 100%

75 %
75 % 75 %

50 % 50 % 50 %

Tensile Tensile Tensile

25 % 25 % 25 %
Densit y strength Densit y strength Densit y strength
0% at yield 0% at yield 0% at yield

Notched Izod Tensile elongation Notched Izod Tensile elongation Notched Charpy Tensile elongation
at break at break at yield

KetaSpire® PEEK AM (3D printed) Radel® PPSU AM (3D printed) Solef ® PVDF AM (3D printed)
KetaSpire® PEEK (injection molded) Radel® PPSU (injection molded) Solef ® PVDF (compression molded)

KetaSpire® KetaSpire® CF Radel® Solef ® Test

Typical Property Unit PEEK AM PEEK AM PEEK AM PVDF AM method
General
Filament diameter mm 1.75 1.75 1.75 2.85

Density g/cm3 1.29 1.33 1.29 1.72 ISO 1183

Mechanical
Tensile modulus* GPa 3.12 11.0 2.0 0.8 ASTM D638

Tensile strenght at break* MPa 48 140 42 25 ASTM D638

Tensile strenght at yield* MPa 85 – 62 30 ASTM D638

Tensile elongation at break* % 26 1.7 21 50-250 ASTM D638

Tensile elongation at yield* % 4.8 – 7.0 10 ASTM D638

Notched izod impact J/m 81 89 482 – ASTM D256

Thermal
Melting temperature °C 343 343 (Tg = 220) 148 ASTM D3418

Printing conditions
Filament drying conditions: °C 150 150 150–170 Not needed
minimum temperature, 4h

Extruder temperature °C 390 – 405 390 – 405 380 – 400 225–235

Bed temperature °C >200 >200 180–200 100

* Test Specimen parameters: Type V bars

For Ketaspire® PEEK AM and Radel® PPSU AM:

1st layer: 0.3 mm thick, subsequent layers: 0.1mm; 100% infill, 3 shells, printing speed 18mm/s. Printing tool path: Cross hatching in the XY plane

For Ketaspire® PEEK CF AM:

1st layer: 0.3 mm thick, subsequent layers: 0.1mm; 100% infill, 3 shells, printing speed 18mm/s. Printing tool path: 0°

For Solef® PVDF AM:

Layer: 0.2 mm thick, 100 % infill, 3 shells, printing speed: 25 mm/s. Printing tool path: Cross hatching in the XY plane

Please reference our Processing Guide for handling and safety instructions. Adequate ventilation is required to prevent possible toxic fumes. Proper handling is essential.

Delivering on the promise of Additive Manufacturing /9

 Our new medical grade AM-ready filaments
Due to its demanding design, low volumes and high
customization need, the Healthcare industry is one of
the key markets to benefit from Additive Manufacturing
technology, but while brand new 3D printers specifically
targeting the Healthcare industry are already in
development, the choice of high-performance medical
grade filaments is still very limited.
We are proud to provide new high-performance solutions
that will enable 3D-printed applications to take on the
challenges of the Healthcare industry, thanks to our
medical grade filaments:
They allow access to a whole new range of limited
exposure applications (having less than 24 hours
contact with bodily fluids and tissue) such as surgical
instruments and devices.
For example:
• cutting guides
• personalized surgical instruments
• small complex components to be used
in medical devices

• KetaSpire® PEEK AM Filament NT1 HC,

• KetaSpire® PEEK AM Filament CF10 HC
• Radel® PPSU AM Filament NT1 HC

Biocompatibility
As an established materials supplier to the healthcare industry, we understand the industry’s global biocompatibility
concerns and offer comprehensive regulatory support.

• ISO 10993 Limited contact testing with Master Access File support
• Global regulatory specialists to support medical device submissions and data requests

Biocompatibility testing

Test Method KetaSpire® PEEK Radel® PPSU

Physico-chemical ISO 10993-18 √ √

Cytotoxicity ISO 10993-5 √ √

Sensitization ISO 10993-10 √ √

Intracutaneous toxicity ISO 10993-10 √ √

Acute systemic toxicity ISO 10993-11 √ √

10 \ Delivering on the promise of Additive Manufacturing

How-to use Solvay AM-ready materials
In order to ensure you obtain the best results we would
also like to share our knowledge and experience regarding
Design and Equipment.
Design Principles chosen equipment meet specific requirements:
Parts made using Solvay AM-ready filaments should be
designed in the same manner as parts fabricated from
other polymeric materials:
• A part file should be generated using computer aided
design software.
• The physical characteristics of the part itself along with
printer slicing parameter settings will determine the
build tool path.
• This path will then create a part microstructure that
will result in a given set of finished part mechanical
properties.
Additional considerations such as the effect of highly
oriented carbon fiber in printed KetaSpire® CF PEEK AM
can impart anisotropy in properties which should be taken
into account when choosing fill patterns. A final brim will
be critical to establishing stability of the part.
Equipment Requirements
It is important in the case of printing Radel® PPSU AM,
KetaSpire® PEEK AM, and KetaSpire® CF PEEK AM that
• High temperature capabilities of chosen equipment.
• Die tooling must be able to be heated to temperatures
up to 450 °C (842 °F) and bed temperatures should
be capable of achieving temperatures of 150 – 200 °C
(300 – 400 °F). Cooling mechanisms for stepper motors
are advised.
• Excellent temperature control for the printing head is
also important as it prevents overheating and excessive
residence time when the print head is stationary.
• Adhesion to the base should be achieved by using a
compatible surface to the material being printed that
promotes adhesion either chemically or mechanically.
It should also be implemented in a way that it can be
replaced if damaged or worn.
• Adjust build plate temperature or adhesion surface.

How to order online

We want you to take 3D printing to the next level starting from NOW!
So, we’ve launched a new e‐commerce platform at www.solvayamshop.com.

This platform is designed to provide a better customer experience to the fast‐growing number of AM technology users by
giving you quick, direct access to Solvay’s advanced AM material solutions, as well as transparent pricing.

Stay tuned… the site will also serve as a portal to a series of simulation, testing, and prototyping services that
leverage Solvay’s growing partner network and open ecosystem approach.

Find out more at www.solvayam.com

Delivering on the promise of Additive Manufacturing / 11

 Specialty Polymers
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www.solvay.com

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