Rapid Prototyping Guide: Methods, Materials, and Process Selection
A breakdown of FDM, SLA, SLS, MJF, and CNC machining for prototype development: when to use each, how to match process and material to your validation goal.
Read the ArticlePC-FR 3D Printing Material
Fused Deposition Modeling (FDM) · High-Temp
Flame-retardant polycarbonate with high strength and heat resistance.
What Is PC-FR?
PC-FR is a flame-retardant polycarbonate engineered for high impact strength, thermal stability, and UL 94 V-0 rated fire resistance. It is built for industrial, electrical, and transit applications that demand mechanical durability together with flame retardancy.
Flame-Retardant Polycarbonate, printed with Fused Deposition Modeling (FDM). Every order is reviewed by our engineering team - no minimum order quantity.
When to choose PC-FR
Choose PC-FR when your part requires flame retardancy and real mechanical strength. Its UL 94 V-0 rating means it self-extinguishes quickly and does not drip flaming particles - a hard requirement for electrical enclosures, battery housings, transit interior parts, and any application governed by fire safety codes.
PC-FR is also one of the strongest FDM materials we print at 60 MPa tensile, significantly outperforming ABS (33 MPa) and ASA (37 MPa). If strength is the driver and flame retardancy is a bonus, PC-FR delivers. Its 113 °C HDT puts it well above ABS and ASA territory.
For higher temperature applications (above 130 °C), ULTEM 9085 and ULTEM 1010 are the next steps up, but at significantly higher cost and longer lead times. PC-FR is our most capable high-performance FDM material.
Material Properties
Representative values - process- and orientation-dependent. Full technical datasheet available on request.
Process
Fused Deposition Modeling (FDM)
Tensile strength
60 ± 4 MPa
Elongation at break
5–8%
Flexural modulus
1,890 ± 70 MPa
Heat deflection (HDT)
113 °C @ 0.45 MPa
Density
1.20 g/cm³
Max build size
245 × 245 × 230 mm
Min wall thickness
1.0 mm
Resolution / layer
150 µm
Relative cost
$$ (1 = lowest, 4 = highest)
Design Guidelines
Plan features to print reliably and assemble cleanly in PC-FR. Need DFM help?
Min wall
1.0–1.5 mm - 1.6 mm+ for load
Min hole Ø
1.5 mm - ream for precision
Clearance
0.4–0.6 mm - fit & moving parts
Max size
245 × 245 × 230 mm - larger via split & bond
Dimensional tolerances
Typical tolerance is ±0.35 mm or ±0.5%. PC-FR has moderate shrinkage and requires careful chamber temperature management to achieve consistent accuracy. Large parts (>150 mm in any axis) may see increased warp; uniform wall design and strategic orientation are critical. Post-machining is available for critical features - PC drills and taps cleanly.
Printing notes
PC-FR prints at 260–280 °C nozzle / 100–120 °C bed and requires a fully enclosed, actively heated chamber held at 60–70 °C ambient. This is one of the most demanding FDM materials to print reliably. PC-FR is extremely moisture-sensitive - we dry at 80 °C for 8+ hours and print from a dry-box to maintain filament quality throughout the job. Undried PC-FR produces weak, bubbly parts with delamination. Support removal requires care as the material is stiff; we orient to minimize supports on critical surfaces. Standard brass nozzles work, though hardened steel is preferred for long-run reliability.
How PC-FR Compares
PC-FR alongside related materials.
| PC-FR | ULTEM 9085 | ABS-GF | ABS | |
|---|---|---|---|---|
| Tensile strength | 60 ± 4 MPa | 42–69 MPa | 36 ± 3 MPa | 33 ± 3 MPa |
| Heat deflection (HDT) | 113 °C @ 0.45 MPa | 153 °C @ 1.82 MPa | 99 °C @ 0.45 MPa | 87 °C @ 0.45 MPa |
| Flexural modulus | 1,890 ± 70 MPa | 2,050–2,300 MPa | 2,860 ± 130 MPa | ≈ 2,200 MPa |
| Elongation | 5–8% | 5–6% | 3–5% | 10–15% |
| Density | 1.20 g/cm³ | 1.34 g/cm³ | 1.12 g/cm³ | 1.05 g/cm³ |
| Relative cost | $$ | $$$$ | $$ | $$ |
When to Use PC-FR
Where PC-FR fits, where it doesn't, and what to use instead.
Electrical enclosures and junction boxes
UL 94 V-0 self-extinguishes in <10 seconds without dripping flaming particles - a hard requirement for NEC- and IEC-governed enclosures.
EnergyAerospace and rail interior panels
60 MPa tensile at 1.20 g/cm³ delivers a strength-to-weight ratio competitive with aluminum sheet for non-primary structural interior panels.
AerospaceIndustrial brackets and structural mounts
At 60 MPa tensile - nearly 2x ABS - PC-FR carries real structural loads in motor mounts, conveyor bracketry, and control-cabinet internals.
EngineeringBattery and power-electronics housings
113 °C HDT combined with flame retardancy meets the thermal-runaway safety margins required for lithium-ion battery pack enclosures and EV charger housings.
AutomotiveTransit and marine flame-rated components
Satisfies UL 94 V-0 for transit authorities and marine certifiers that mandate flame-rated materials in passenger compartments.
AerospaceStrengths
- UL 94 V-0 flame retardancy - self-extinguishes quickly, does not drip burning material, meets electrical and transit fire codes
- 60 MPa tensile strength - nearly double ABS (33 MPa) and 60% above ASA (37 MPa)
- 113 °C HDT bridges the gap between commodity ABS (87 °C) and premium ULTEM (153 °C) at a fraction of ULTEM's cost
Keep in mind
- Requires enclosed chamber at 60–70 °C ambient with 260–280 °C nozzle - the most demanding FDM print conditions in our shop
- Extremely moisture-sensitive - must be dried at 80 °C for 8+ hours; undried PC-FR produces delaminated, structurally compromised parts
- Does not vapor-smooth or take acetone finishing - surface options are sanding and painting only; use ABS for cosmetic acetone-finish parts
Finishes & Colors
Finishing options and in-stock colors for PC-FR.
Standard
As-printed with support removal; matte surface.
Best for: Functional industrial parts
In-Stock Colors
Black
White
Custom colors and dyeing available on request. Contact us for options.
PC-FR FAQ
V-0 is a flammability rating indicating the material self-extinguishes quickly and does not drip flaming particles. It is often required for electrical and transit components. Ask us about documentation for your application.
PC-FR is significantly stronger and more heat-resistant than ABS, with the added benefit of flame retardancy - at a higher process cost.
PC-FR (113 °C HDT, UL 94 V-0) handles most flame-retardant applications at lower cost. ULTEM 9085 (153 °C HDT, FST-rated) is necessary for aerospace and transit applications requiring FAR 25.853 or similar smoke/toxicity compliance, and for temperatures above 130 °C.
Yes. PC-FR's flame retardancy, high strength, and heat resistance make it well suited to battery pack housings and power-electronics enclosures. Design adequate ventilation and wall thickness per your safety requirements.
Very. PC-FR must be thoroughly dried (80 °C, 8+ hours) before printing. Undried PC produces weak, delaminated parts with visible bubbles. We maintain strict drying protocols and print from dry-box enclosures.
We hold ±0.35 mm or ±0.5% on PC-FR parts. The material has moderate shrinkage that we control with heated-chamber management. For tight-tolerance features, we can ream and drill after printing.
Polycarbonate has moderate UV resistance - better than ABS but not as good as ASA. For indoor industrial and electrical applications, PC-FR performs well long-term. For sustained outdoor sun exposure, consider ASA if flame retardancy is not required.
No. PC-FR does not respond to acetone vapor smoothing like ABS. Surface finishing is limited to sanding and painting. The as-printed matte surface is appropriate for most industrial applications.
Technical Documents
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