Polycarbonate printing Has anyone extruded and/or printed with PC? I really fancy having a go at using it. Any feedback on using it or worries etc? [url=http://en.wikipedia.org/wiki/Polycarbonate]http://en.wikipedia.org/wiki/Polycarbonate[/url] Cheers, Rich. https://reprap.org/forum/read.php?184,90290,90290#msg-90290 Sun, 08 Mar 2026 06:17:10 -0400 Phorum 5.2.23 https://reprap.org/forum/read.php?184,90290,494254#msg-494254 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,494254#msg-494254

]]> rsilvers Polymer Working Group Wed, 08 Apr 2015 10:07:22 -0400 https://reprap.org/forum/read.php?184,90290,494112#msg-494112 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,494112#msg-494112
A few layers of glue stick on bare glass (which is what I use for any filament). I use the purple kind.

Bed at 110-120C, but I started a print a 90 and that worked also, so I can't say that it must be 110 or more. I am getting more an more casual about not waiting for it to heat up and no problems so far.

Print speeds no higher than 60 mm/sec for best quality. I did 80 mm/sec and it was just detectably worse on inner curves, though still ok for a "fast" mode.

290C worked even with 300 micron layers 0.48mm wide at 80 mm/sec, so I see no reason to go higher temp.

100 micron layers had much stronger bonding than 300 micron layers.

Flat parts don't need a brim. Tall parts need a brim.

No strings at all.

PC won my pull test, with PolyMax coming in second. eSun PETG is an awesome material:

[forum.makergear.com]

This was my first part. Flat and easy, but the tall 0.5 lb part came out perfect also.


]]> rsilvers Polymer Working Group Wed, 08 Apr 2015 00:58:48 -0400 https://reprap.org/forum/read.php?184,90290,166969#msg-166969 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,166969#msg-166969 -------------------------------------------------------
> Hey richrap can you go into details of your
> extruder and how you were able to achieve high
> enough temps to extrude PC?

There's nothing secret in it, you can go and just buy an extruder which works at 270-300 degrees. Arcol.hu makes one, and there are other makers as well. I guess you could make one yourself too, just make sure that everything in the hot side is metal or ceramic. (So no PEEK, no PTFE)]]> ttsalo Polymer Working Group Mon, 19 Nov 2012 11:12:33 -0500 https://reprap.org/forum/read.php?184,90290,163590#msg-163590 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,163590#msg-163590
Thanks
Dan]]> Daniel Stein Polymer Working Group Tue, 30 Oct 2012 23:24:15 -0400 https://reprap.org/forum/read.php?184,90290,161836#msg-161836 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,161836#msg-161836 Forgot to mention: nozzle is .35mm extrusion width .38 and layer height of .20

I tried to print a cat toy and it was to week at 275, i think that the temp needs to more like 300. The planes print are only a couple mm tall so i think as the taller objects are cooler because they dont get the benefit of the heat from the bed.]]> Gulf Polymer Working Group Sat, 20 Oct 2012 11:53:18 -0400 https://reprap.org/forum/read.php?184,90290,160131#msg-160131 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,160131#msg-160131 xiando Polymer Working Group Thu, 11 Oct 2012 17:20:34 -0400 https://reprap.org/forum/read.php?184,90290,160077#msg-160077 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,160077#msg-160077 www.thingiverse.com]
her is a link to the first one I printed before he added a version with a "beard" to keep the front of the plane down.
[www.thingiverse.com]
The plane is very durable compared to the PLA one I printed, and a lot of fun.

My settings were extruder 270-280 and bed temps of 110-115.]]> Gulf Polymer Working Group Thu, 11 Oct 2012 12:23:11 -0400 https://reprap.org/forum/read.php?184,90290,155496#msg-155496 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,155496#msg-155496 raldrich Polymer Working Group Thu, 20 Sep 2012 04:15:43 -0400 https://reprap.org/forum/read.php?184,90290,154373#msg-154373 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,154373#msg-154373
That said, at least my hot-ends always have some slowly decomposing plastic stuck around the nozzle and a long term exposure to the fumes can't be a good thing no matter what the plastic type is. So ventilating to outside air or perhaps using an active carbon filter would be a good idea in any case.]]> ttsalo Polymer Working Group Fri, 14 Sep 2012 08:43:14 -0400 https://reprap.org/forum/read.php?184,90290,151965#msg-151965 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,151965#msg-151965
Parsed from: [www.perspex.co.uk]

"Unlikely to be hazardous by inhalation. High concentrations of vapour from hot operations may be harmful,
cause irritation of the respiratory tract."

Article goes on to say the decomposition components (decomposition temp is ~400C) are "Hydrocarbons, Phenol, Carbon Monoxide"

So then phenol, considering that CO is pretty well known, and "hydrocarbons" is too vague to chase

Phenol:
From [www.osha.gov]

"Effects on Humans: The effects of phenol exposure in humans are similar to those produced in animals: systemic absorption causes central nervous system impairment and liver and kidney damage; local effects include irritation of the eyes, skin and mucous membranes[Hathaway et al. 1991]. Because of its low volatility, phenol does not pose a serious inhalation hazard in the occupational setting; the skin is a primary route of entry [Hathaway et al. 1991; Parmeggiani 1983]."

I would think that would be the normal case, ie, it's pretty safe as long as we don't over-heat it, but seeing that these rigs are experimental, accidents happen, heaters go full up, etc. so it's better safe than sorry.]]> xiando Polymer Working Group Sun, 02 Sep 2012 12:24:45 -0400 https://reprap.org/forum/read.php?184,90290,151878#msg-151878 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,151878#msg-151878
I don't know off hand what the exact volatiles are and couldn't find them quickly enough to avoid getting frustrated with google, so...

This quote from the AMtrust group plastic mfg safety guide says it all as far as I'm concerned. I bolded the rightfully alarming stuff.

"Plastics processing generates a variety of toxic dusts, vapors and fumes from the molding, forming and extruding of plastics. Resins, various chemical additives and modifiers present a significant chemical exposure hazard for production workers. Some commonly used hazardous chemicals are ketones, polyvinyl acetate, styrene, mineral spirits and acetones. Studies show that plastics processing workers have elevated risks of liver cancer and brain tumors because some plastics processing chemicals contain carcinogens. Other associated ailments are heart and kidney disease, occupational dermatitis and various long-term respiratory problems.

Inherently hazardous to workers, welding activities present health hazards from noise, electric shock, fires and explosions, and exposure to welding smoke (gases and fumes). Welding smoke can lead to acute or chronic respiratory diseases, carcinoma of the lungs, eye irritation, skin irritation, skin cancer, reduced sperm count and motility, and infertility.

Flammable solvents for degreasing, parts cleaning and chemical treatment operations are noted for long-term adverse health effects. The negative effects include elevated risks of liver and kidney disease, respiratory illness, dermatitis, allergic reactions and cancer."

I know that some naive kids will scoff and call me a kook and do their best to discount it as hersay or boooring, but having worked in an environment that was thick with the fumes of Stoddard fluid for ~7 years, I've learned that it's better to be cautious. (I won't be getting cancer from it afaik, but it did give me some serious headaches and made me pretty queasy after a while, and even after I left the job, I could still "taste" it in my food for months and smell it in my clothes, no matter how many times I washed them. One shirt and a pair of jeans that got thoroughly soaked due to a spray nozzle that got away from me during testing went to an early grave in the garbage they were so bad.)

When in doubt, ventilate. Why learn that you *should have been, 20 years later when your kid is getting ready to graduate from highschool, or you've finally retired from the daily grind with things left to do? And inline vent fan, some dryer vent flex tub, and a bit of creativity pumps it outside, away from your lungs, your partner's lungs, your pet's lungs, and your children's lungs. Especially your children's lungs.

Anyone who's done a good deal of soldering without a fume extractor understands. A little bit almost smells nice, or at least just smells "interesting". After a while though and it's cloying, and after a while longer it's just plain nasty. And by "while" I don't mean a couple hours, I mean a few months or years.

ymmv and your choices are ultimately yours.

PS...I almost forgot to ask the question that led me here in the first place. What heated-bed temperature are you using for PC extrusion? I'm building up my first system and want it as flexible to start as possible. I know nylon and PC run at higher extrusion temps so I assume the heated bed temp is higher than for ABS as well (power supply rating, etc.)]]> xiando Polymer Working Group Sat, 01 Sep 2012 20:22:59 -0400 https://reprap.org/forum/read.php?184,90290,150990#msg-150990 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,150990#msg-150990
can anyone supply info about the gas emitted during a print? i hear it will require a good extractor, its poisonous? yes? no?]]> redreprap Polymer Working Group Tue, 28 Aug 2012 11:40:31 -0400 https://reprap.org/forum/read.php?184,90290,149985#msg-149985 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,149985#msg-149985
The smell when extruding is not bad, PC smells better than even high quality ABS. But it's still probably not really good for you...]]> ttsalo Polymer Working Group Thu, 23 Aug 2012 12:46:38 -0400 https://reprap.org/forum/read.php?184,90290,149290#msg-149290 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,149290#msg-149290 -------------------------------------------------------
> also,
> [www.protoparadigm.com]
> -polycarbonate/ = pure PC or PC/ABS ?

Pure PC. I have some of it to play with, though I haven't extruded any of it yet.

Not sure about fumes, though the MSDS only has a warning for fumes above the decomposition temperature, which is hotter than we would ever want to extrude it at.]]> NewPerfection Polymer Working Group Sun, 19 Aug 2012 22:14:23 -0400 https://reprap.org/forum/read.php?184,90290,149283#msg-149283 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,149283#msg-149283
im interested to know what mods to the hotend? nichrome wire type to get to up to 330c ?

also, [www.protoparadigm.com] = pure PC or PC/ABS ?

are there any toxic fumes to be wary of for PC printing?

im trying to find materials that wud be above 80c crystalization :D]]> redreprap Polymer Working Group Sun, 19 Aug 2012 21:32:39 -0400 https://reprap.org/forum/read.php?184,90290,142200#msg-142200 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,142200#msg-142200
It also has some properties which are better than ABS's:

* Filament won't strip, E motor will just skip steps even at max current
* More fluid, but still solidifies easier. Small things which ended up being a blob of jello when printing with ABS printed fine with PC. Except the bridge... I couldn't get the bridging to work at all.
* Overhangs printed really well]]> ttsalo Polymer Working Group Wed, 11 Jul 2012 05:55:50 -0400 https://reprap.org/forum/read.php?184,90290,140845#msg-140845 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,140845#msg-140845 Andrew Diehl Polymer Working Group Sun, 01 Jul 2012 21:37:23 -0400 https://reprap.org/forum/read.php?184,90290,140807#msg-140807 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,140807#msg-140807
Decent in this case is perhaps 3 cubic inches.

I haven't printed with it in a while, I need to. It's a pretty fun plastic, even if you have to play around with it more than ABS or PLA.

Let us know if fatter traces help the cracking.]]> Luke C Polymer Working Group Sun, 01 Jul 2012 15:43:18 -0400 https://reprap.org/forum/read.php?184,90290,140104#msg-140104 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,140104#msg-140104
Feed-Rate 25mm/s perimeter, 50mm/s fill, 200mm/s travel.

Printer: Fablicator

Hotend: Custom, .35mm orifice, direct drive, 1.75mm filament. No problem maintaining 330C.

I've been doing everything pretty much exactly the same as ABS (no fan, 120C bed, .4mm width, .25mm thick layers)

How big is "Decent Size?" I pull the Kapton right off the bed on all but the smallest prints.

Have you tried doing thin walled parts like the stratasys twisted bottle?

Thanks,

Andrew]]> Andrew Diehl Polymer Working Group Tue, 26 Jun 2012 19:10:26 -0400 https://reprap.org/forum/read.php?184,90290,139921#msg-139921 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,139921#msg-139921
What layer heights/widths

Feed-Rate?

Printer?

Hotend?

It seems the thicker, wider layers definitely help with adhesion. Doing so increases the flowrate which can increase the required temperature. One trick is to go slow and print as cool as possible, this is especially true if you aren't using a heated chamber. It seems the sharp temperature differential makes the PC want to contract, heat up the air or lowering the extrusion temp seems to help. Seemingly contradictory, so can a fan. A fan blowing warm air can get some of that contraction all done and out of the way so it doesn't happen after you've got a nice long printed trace trying to buckle your print.

As for the heated bed, hotter is better but not required. I'm able to get decent sized prints done on the Ultimaker using an ABS/acetone slurry painted before hand. Though you said you've already tried that; does the PC detach from the Kapton with the ABS Slurry, or does it pull the Kapton tape off the bed?]]> Luke C Polymer Working Group Tue, 26 Jun 2012 01:23:36 -0400 https://reprap.org/forum/read.php?184,90290,139907#msg-139907 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,139907#msg-139907
It extrudes wonderfully, but I just can't get it to behave at all so far.

Any thoughts or similar experiences?]]> Andrew Diehl Polymer Working Group Tue, 26 Jun 2012 00:00:41 -0400 https://reprap.org/forum/read.php?184,90290,112137#msg-112137 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,112137#msg-112137 Have Blue Polymer Working Group Tue, 03 Jan 2012 17:45:15 -0500 https://reprap.org/forum/read.php?184,90290,111954#msg-111954 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,111954#msg-111954
Here is a link to our post about printing with polycarbonate.


We've been really impressed with its properties.

Good luck!

Alex]]> ProtoParadigm Polymer Working Group Mon, 02 Jan 2012 05:44:02 -0500 https://reprap.org/forum/read.php?184,90290,111929#msg-111929 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,111929#msg-111929 Luke C Polymer Working Group Mon, 02 Jan 2012 00:02:51 -0500 https://reprap.org/forum/read.php?184,90290,111429#msg-111429 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,111429#msg-111429 Have Blue Polymer Working Group Wed, 28 Dec 2011 13:32:41 -0500 https://reprap.org/forum/read.php?184,90290,110881#msg-110881 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,110881#msg-110881 We'll have an official post up going over our experience with PC soon but we did add Polycarbonate to our product lineup. The current listing is a pre-order and will ship January 30, 2012. Shipping within the US is included in the price with world wide shipping available for an extra $9.00. The filament is extruded to standard 3mm and 1.75mm so no more trouble dealing with 1/8" or 1/16" (that was the 1.6mm people were using).
Find it here:

1.75mm PC

3mm PC

Happy Printing

Luke
luke(at)protoparadigm(dot)com]]> ProtoParadigm Polymer Working Group Thu, 22 Dec 2011 05:55:54 -0500 https://reprap.org/forum/read.php?184,90290,108537#msg-108537 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,108537#msg-108537 L4nce0 Polymer Working Group Thu, 01 Dec 2011 18:37:41 -0500 https://reprap.org/forum/read.php?184,90290,103531#msg-103531 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,103531#msg-103531
PC/ABS is a great material, it's impact resistance is why cell phones, dash boards, and laptops are made out of it.

I saw that Nophead has tried acrylic, but haven't seen if anyone else has tried it. I would be curious to know the brands and grades of Acrylic that have been tried. I have some Atofina Plexiglass V052 (their injection molding grade Acylic). If Acrylic can be used, this is the grade. The other acrylic filament rods that is available is an extrusion grade, very slow moving stuff.

I'm also curious if anyone has tried either High Impact Polystyrene, or regular Crystaline Polystyrene? Their shrink factor is the same as ABS, and PS adheres very well to itself. Straight PS is clear, and could be used for light refractions in things like Christmas Ornaments, etc... PS is also Non-Hydroscopic, it requires no drying for processing into filament and wouldn't absorb moisture over time to degrade it's performance.

In the next couple of weeks, I will be extruding some PC, PC/ABS, Acrylic, HIPS, and ABS resins into 1.75mm filament for testing. I have selected grades that I believe have the most favorable specs for being able to extrude them for 3D prints. Anyway, if anyone is interested in testing any of these, let me know.

Oh, my disclaimer: "I break things in order to make better things."]]> TreaterBot Polymer Working Group Thu, 27 Oct 2011 02:41:48 -0400 https://reprap.org/forum/read.php?184,90290,103477#msg-103477 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,103477#msg-103477
I also noticed a mix of ABS+PC - how about that? Maybe it would increase the abs strength without warping too much in exchange.

Anybody tried that?]]> NoobMan Polymer Working Group Wed, 26 Oct 2011 18:41:35 -0400 https://reprap.org/forum/read.php?184,90290,101323#msg-101323 Re: Polycarbonate printing https://reprap.org/forum/read.php?184,90290,101323#msg-101323
> I have extensively run both methods at this point,
> and have noticed absolutely no difference of
> quality either way.
In regular extrusion as long as your E values are within the "chew-size" of the FW thats true. I fully agree.
>
> I'm not convinced the firmware doesn't deal with
> them properly already, though. If I send 1000
> 1/1000th of a step extrude commands, does the
> firmware round each one down to zero, or does it
> internally sum them up and send a pulse when
> appropriate?
Well I tried it out thats why I am concerned. (Take the Hellokitty face file here: http://dl.dropbox.com/u/38819298/HK_20mm.stl and skein it at 0.2*0.2 mm
then look at the last layers perimeter.,
With absolute E values and Extra decimals set to 2
******
( outer )
G1 X104.6291 Y99.5811 Z6.2 F900.0 E0.0002
G1 X104.661 Y99.5897 Z6.2 F900.0 E0.0003
G1 X104.6931 Y99.7183 Z6.2 F900.0 E0.0003
G1 X104.6865 Y100.1821 Z6.2 F900.0 E0.0003
G1 X104.6576 Y100.2293 Z6.2 F900.0 E0.0003
G1 X104.5446 Y100.2123 Z6.2 F900.0 E0.0003
G1 X104.5033 Y100.1354 Z6.2 F900.0 E0.0003
G1 X104.4691 Y99.9138 Z6.2 F900.0 E0.0003
G1 X104.473 Y99.7529 Z6.2 F900.0 E0.0004
G1 X104.5045 Y99.6398 Z6.2 F900.0 E0.0004
******
And all same settings just extrusion changed to Relative distances.
( outer )
G1 X104.6291 Y99.5811 Z6.2 F900.0 E0.0
G1 X104.661 Y99.5897 Z6.2 F900.0 E0.0
G1 X104.6931 Y99.7183 Z6.2 F900.0 E0.0
G1 X104.6865 Y100.1821 Z6.2 F900.0 E0.0
G1 X104.6576 Y100.2293 Z6.2 F900.0 E0.0
G1 X104.5446 Y100.2123 Z6.2 F900.0 E0.0
G1 X104.5033 Y100.1354 Z6.2 F900.0 E0.0
G1 X104.4691 Y99.9138 Z6.2 F900.0 E0.0
G1 X104.473 Y99.7529 Z6.2 F900.0 E0.0
G1 X104.5045 Y99.6398 Z6.2 F900.0 E0.0

And Extra Decimals set to 4:
absolute:
( outer )
G1 X104.629137 Y99.581152 Z6.2 F900.0 E0.000249
G1 X104.661083 Y99.589734 Z6.2 F900.0 E0.000251
G1 X104.693155 Y99.718223 Z6.2 F900.0 E0.000262
G1 X104.686558 Y100.182052 Z6.2 F900.0 E0.0003
G1 X104.657666 Y100.229229 Z6.2 F900.0 E0.000304
G1 X104.544659 Y100.21229 Z6.2 F900.0 E0.000314
G1 X104.503349 Y100.135409 Z6.2 F900.0 E0.000321
G1 X104.469215 Y99.913782 Z6.2 F900.0 E0.000339
G1 X104.473112 Y99.752913 Z6.2 F900.0 E0.000352
G1 X104.504506 Y99.639768 Z6.2 F900.0 E0.000362
relative:
G1 X104.629137 Y99.581152 Z6.2 F900.0 E2.3e-05
G1 X104.661083 Y99.589734 Z6.2 F900.0 E3e-06
G1 X104.693155 Y99.718223 Z6.2 F900.0 E1.1e-05
G1 X104.686558 Y100.182052 Z6.2 F900.0 E3.8e-05
G1 X104.657666 Y100.229229 Z6.2 F900.0 E4e-06
G1 X104.544659 Y100.21229 Z6.2 F900.0 E9e-06
G1 X104.503349 Y100.135409 Z6.2 F900.0 E7e-06
G1 X104.469215 Y99.913782 Z6.2 F900.0 E1.8e-05
G1 X104.473112 Y99.752913 Z6.2 F900.0 E1.3e-05
G1 X104.504506 Y99.639768 Z6.2 F900.0 E1e-05

The FW handles the Exp expression but all of these values remain below the threshold of a stepper move.
As the FW does not add up the previous values in any way they are just lost.
In Absolute extrusion assuming your Stepper steps at 1/1000 mm you would at least get "some" movement in every 4th command..]]> ahmetcemturan Polymer Working Group Fri, 14 Oct 2011 03:57:13 -0400