PLA Tough Ultrafuse

The BASF Ultrafuse PLA Tough biobased filament is part of the broad Ultrafuse range of engineering materials for FFF 3D printing, manufactured on state-of-the-art computer-controlled machinery. Ultrafuse PLA Tough is available in diameters of both 1.75 mm and 2.85 mm, and in spool sizes ranging from 750 g to 8 kg. Thanks to the careful manufacturing methods, the Ultrafuse filament colors and diameters are consistent, and the materials always perform thermomechanically.

Video 1: Introducing the PLA Tough Ultrafuse filament. Source: BASF.

Ultrafuse PLA Tough was designed specifically for professional users in various industries, having in mind as the goal to streamline the production of large components and complex geometries (with the help of the water-soluble BVOH support material), saving time and costs while ensuring top-notch quality, including sharp details in small parts.

Image 1: PLA Tough is ideal for printing complex and large parts. Source: BASF.

PLA Tough Ultrafuse effortlessly accommodates high printing speeds up to 300 mm/s without requiring hardware adjustments, ensuring an outstanding surface finish and impressive impact strength. Printing profiles for printers such as the Raise3D Pro3 or the Bambu Lab printers can be found in the Downloads section.

Properties and performance

PLA Tough Ultrafuse serves as a sustainable and robust alternative to ABS (133 % stronger), delivering superior mechanical performance and ease of printing.

Image 2: A comparison of properties of PLA Tough and other PLA materials. Source: BASF.

PLA Tough Ultrafuse not only boasts an impressive 720 % higher impact strength than standard PLA, but 3D printed parts can be further strengthened through a separate annealing process, increasing toughness by up to 230 % and heat resistance by 257 %.

Annealing

In the process of plastic annealing, PLA is heated to a temperature slightly lower than its melting point to relieve internal stresses and rearrange the PLA’s molecular chains towards more semi-crystalline structures.

Image 3: Annealing a part 3D printed with PLA Tough. Source: BASF.

Annealing instructions can be found in the Usage Tips section and detailed pre- and post-annealing technical data can be consulted in the product's technical datasheet available in the Downloads section.

Biocompatibility

A notable characteristic of the PLA Tough Ultrafuse filament is that it has passed extensive biocompatibility experiments for cytotoxicity (XTT neutral red, ISO 10993-5), skin irritation (ISO10993-10), and skin sensitization (LLNA KretinoSens ISO10993-10). The documentation can be found in the Downloads section.

Image 4: Biocompatible ortheses 3D printed with PLA Tough. Source: BASF.

This makes parts 3D printed with this material suitable for skin contact applications in healthcare. It must be kept in mind, however, that the biocompatibility of the final part depends on the correct processing of the material and should always be assessed independently.

Post-processability

Furthermore, the appearance of the parts 3D printed with the PLA Tough Ultrafuse can be improved by smoothing (e.g. with sandpaper) or painting the printed part to conceal layer lines and imperfections, thus giving the 3D printed part a shiny and glossy appearance. First, a retouching tool should be used to remove any surface imperfections. Then the part can be sanded and covered with a paint primer or epoxy coating such as XTC-3D or the Nanovia smoothing coating to give it a smooth glossy finish.

Applications

The PLA Tough Ultrafuse filament finds extensive applications across multiple sectors. For hobbyists, it's a durable choice for detailed projects. Professionals, including engineers and designers, benefit from its enhanced toughness and speed for prototypes and large-scale parts. Industries like healthcare and automotive rely on its rapid prototyping and sustainable production capabilities. Its adaptability suits various applications: jigs & fixtures, orthotics, prototyping, and manufacturing aids, meeting diverse industry needs efficiently.

Image 5: A durable housing 3D printed with PLA Tough. Source: BASF.

BASF strives to provide specialized materials that cater to the different needs of additive manufacturing. While PLA Tough Ultrafuse is ideal for fast and reliable printing in engineering applications, there are alternatives for more aesthetic applications. For beginners looking to print colorful parts with no mechanical requirements an interesting alternative is the Ultrafuse PLA. For parts that need to have impeccable aesthetics for premium projects, it is recommended to use Ultrafuse PLA PRO1.

High speed printing

Furthermore, the PLA Tough Ultrafuse filament is compatible with high printing speeds. In order to create complex structures with this material and a support material, the Xioneer VXL 90 soluble support material is recommended by the manufacturer. This support material can be extruded at high speeds as well, which means a smooth and efficient 3D printing. The water solubility of VXL 90 makes the post-processing more precise and fast. In the Downloads section a table of compatibilities between the BASF Ultrafuse and Xioneer support filaments can be consulted.