Let's Get You Started with Metal 3D Printing!

It is possible to print Ultrafuse® metal filaments with a standard desktop FFF printer, however; the chosen machine and its condition can dramatically influence part accuracy and quality. Similar to traditional FFF materials like ABS, warpage can occur with temperature variations and it is therefore recommended to fully enclose the printing chamber to limit air flow. Printing stability can in some situations benefit from actively heated chambers but are not essential.

Ultrafuse® metal filament causes more nozzle wear than traditional plastic filaments due to its high metal content. Hardened nozzles last longer, but regular brass nozzles can work well if replaced frequently. Replace non-hardened nozzles after every 3kg of filament. Always use new, clean nozzles for Ultrafuse® to avoid hazards to printed parts and debinding/sintering equipment.

At 3 kg (6.6lbs) supplying material from a full spool can be difficult for some printers and can result in under extrusion and other flow issues. Therefore, a spool holder using bearings or other techniques of reducing the required force to deploy filament is recommended. Any number of DIY or commercial options, like the Polymaker PolyBox, have been proven effective.

Ultrafuse® Metal Filaments and the Ultrafuse® Support Layer are supported with leading FFF printers to achieve the best printing performance. The complete overview of supported printers can be found in here: Print Profiles for Ultrafuse® Filaments

Use the following links to download the latest print profile at the machine manufacturers website of your FFF 3D printer.

BASF Ultrafuse® 316L:
Raise 3D
Prusa 
BCN3D
Download at Ultimaker.com

BASF Ultrafuse® 17-4 PH:
Raise 3D
Prusa 
BCN3D
Download via Ultimaker website

BASF Ultrafuse® Support Layer:
BCN3D
Raise 3D

The versatility of BASF Ultrafuse® 316L extends to various applications, including crafting intricate metal end-use parts, functional prototypes, medical devices, automotive components, chemical pipelines or valves, as well as tool or fixture elements. With remarkable tensile strength of up to 561 MPa, yield strength of 251 MPa, and elongation at break of up to 53%, printed parts exhibit an austenitic (non-magnetic) microstructure.

Applications Include:

• Welding-ready parts,
• Tooling, jigs and fixtures.
• Automotive components resistant to corrosion
• Equipment exposed to various chemicals and fluids
• Decorative elements including trims and grilles
• Essential parts within hydraulic systems
• Containers for storing food items
• Medical apparatus and instruments
• Precision mechanisms requiring corrosion resistance

BASF’s Ultrafuse® 17-4 PH is a premium industrial composite filament designed compatible with leading FFF 3D printers. Its advanced properties enable users to produce metal parts easily, safely and cost-effectively, providing a superior alternative to metal injection molding or conventional metal machining. Consisting of 88% 17-4 stainless steel particles and 12% polymer content, this filament delivers exceptional performance.

Available downloads:

BASF Ultrafuse® 17-4 PH VS. BASF Ultrafuse® 316L: See our Full Comparison Sheet for more support on material choice.

The versatility of BASF Ultrafuse® 17-4 PH extends to a wide range of applications, including the production of robust metal end-use parts, functional prototypes, weather resistant elements, medical devices, automotive components, chemical piping or valves, and tooling or jig components. With an impressive tensile strength of up to 1004 MPa, yield strength of 764 MPa and elongation at break of up to 4%, the printed parts have a martensitic (magnetic) microstructure.

Applications Include:

• Functional prototypes,
• Metal end-use parts,
• Elements requiring weather resistance,
• Medical equipment,
• Automotive parts,
• Components for chemical industry,
• Parts intended for welding,
• Customized tooling, jigs, fixtures.

BASF’s Ultrafuse® Support Layer serves as a specialized support filament tailored for metallic powder filaments. Its use is critical to achieving the desired part geometry, ensuring precision during both the 3D printing and post-processing phases*.

Available Downloads:

• Technical Data Sheet: EN, FR, ES, DE
• User Guidelines Support Layer
• Safety Data Sheet: EN, other languages

*Ultrafuse® Support Layer is not available to our customers the USA & CANADA.

For optimal preservation, it’s advisable to store both BASF Ultrafuse® 316L and BASF Ultrafuse® 17-4 PH filaments within temperatures ranging from 15 to 25 °C, preferably in their original packaging. Ensure the storage environment remains clean and dry. Adhering to these recommended storage conditions extends the shelf life of the filaments for up to 12 months.

Due to the dimensions of the ceramic plates used to support 3D prints during post-processing, the maximum allowable size for green parts is 100 x 100 x 100 mm (3.93 x 3.93 x 3.93 in). For larger parts, arrangements must be made with the post-processing service provider, although it’s important to acknowledge that larger parts may be susceptible to warping.

For optimal 3D printing outcomes, it is recommended to adhere to measurements of 60 x 60 x 60 mm (2.36 x 2.36 x 2.36 in).

3D printed parts made with BASF Ultrafuse® 316L and BASF Ultrafuse® 17-4 PH experience shrinkage of approximately 20% in the Z-axis and 16% in the X- and Y-axes during post-processing. This phenomenon needs to be taken into account during the 3D modelling phase by scaling the models to compensate for the expected shrinkage.

Please be advised that in the planned 3D model, a minimum wall thickness of 1 mm (0.03 in) is required. Walls thinner than this specification (1 mm or 0.03 in) may distort during post-processing.

Design unsupported walls with a height-to-width ratio below 6:1 to avoid cracking or collapsing. When using BASF’s Ultrafuse® filaments, use more supports than typical thermoplastics, with angles below 45°. Preferably, design parts to minimize overhangs and the need for extensive supports.

Throughout post-processing, green parts undergo thermal stresses, potentially leading to layer delamination or cracking. Projects featuring notches and sharp edges are particularly susceptible to this layer separation phenomenon. Therefore, incorporating fillets or chamfers into designs is advisable to mitigate such issues.

The correct orientation of models on the platform can impact accuracy, durability, and stability throughout the debinding and sintering phases. Therefore, it’s crucial to orient parts in a manner that maximizes contact between the platform and as many flat surfaces as possible.