In manufacturing medical devices and electronics, the materials used must meet stringent safety and performance standards. For components that require flame retardancy without compromising strength and long-term stability, a specialized material is essential. Enter Epoxy 86FR (EPX 86FR), a flame-retardant additive resin from Carbon that delivers a unique combination of functional toughness, high strength, and reliability. This material is engineered for parts that must perform safely in environments where fire resistance is a critical concern, making it a noteworthy option for many high-stakes industries, including those that have traditionally relied on plastic injection molding services.
EPX 86FR is defined by a set of properties that make it suitable for a variety of demanding end-use parts. Its features are designed to provide safety, durability, and high performance throughout the product lifecycle.
The most prominent characteristic of EPX 86FR is its exceptional flame retardancy. The material is UL 94 V-0 listed at 2 mm thickness and also meets the FAR 25.853(a) vertical burn standard at 1 mm. This means it has self-extinguishing properties, a critical safety feature for electrical enclosures, connectors, and internal components in automotive and aerospace designs. This level of flame resistance is crucial for preventing the spread of fire in sensitive devices and aligns with injection molding quality control standards for critical parts.
Beyond its safety credentials, EPX 86FR provides impressive mechanical properties. With an ultimate tensile strength of 94 MPa, it is a strong and rigid material capable of withstanding significant mechanical stress. This makes it a reliable choice for structural parts like brackets and housings that must maintain their form and function under load. While inherently strong, the material's functional toughness and impact strength can be significantly enhanced through a post-production baking process in an inert oven.
Components in industrial and automotive settings are often exposed to fluctuating temperatures. EPX 86FR demonstrates excellent thermal stability, with a heat deflection temperature of 275°F (135°C). It retains its mechanical properties effectively during high-temperature aging, thermal shock, and exposure to humidity, contributing to the longevity and reliability of the final part. This resilience is vital for parts used in complex assemblies, such as those found in DFM for Medical Devices.
EPX 86FR exhibits notable resistance to various chemicals. According to testing under USCAR-2 conditions, which simulate splash contact with automotive fluids, the material shows minimal change in its tensile properties and no surface blemishes. This resistance is important for parts that may come into contact with cleaners, solvents, or other chemicals during their operational life.
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The distinct properties of EPX 86FR lend themselves to a range of specific end-use parts where safety and performance are paramount.
In both the automotive and consumer electronics industries, connectors and cable clips are often housed in tight spaces where heat can build up. These components frequently require a UL 94 V-0 rating for safety. EPX 86FR is an ideal material for items like high-speed data connectors, offering the necessary flame retardancy, thermal endurance, high accuracy, and toughness to function reliably.
Protective housings and structural brackets for electronics and industrial machinery often need to be flame-retardant, stiff, and temperature-resistant. EPX 86FR provides the required mechanical strength and safety ratings for these parts, along with the benefit of a smooth, high-quality surface finish that is achievable with Carbon's DLS process, making it a viable alternative to injection molding tooling for rapid prototyping services.
For companies familiar with traditional manufacturing methods like injection molding, understanding how EPX 86FR compares to common thermoplastics is key. Carbon identifies flame-retardant Polycarbonate/Acrylonitrile Butadiene Styrene (PC/ABS) and flame-retardant Polycarbonate (PC) as comparable injection molding materials.
Flame-retardant PC/ABS is a popular alloy known for its good processability, toughness, and heat resistance. Like EPX 86FR, it is often used for electronic enclosures and automotive components that require a UL 94 V-0 rating. Both materials provide a good balance of strength and safety. However, EPX 86FR, as a thermoset, generally offers superior thermal stability and resistance to creep over time compared to the thermoplastic PC/ABS blend. Similarly, flame-retardant PC is valued for its strength, impact resistance, and temperature resistance. EPX 86FR shares these qualities, offering comparable stiffness and functional toughness, especially after thermal post-processing. The primary distinction lies in the manufacturing process, with EPX 86FR being tailored for additive manufacturing solutions, which allows for more complex geometries and design iterations without the need for expensive tooling.
While EPX 86FR is a high-performance material, there are some considerations to keep in mind. The material is stiffer and less ductile than some other resins, with a lower elongation at break. This means it is less suitable for parts that require significant flexibility. To achieve its maximum toughness and impact strength, a thermal baking step is required, which adds an extra stage to the production process. Additionally, as a specialized, high-performance resin designed for the Carbon DLS process, it may have different cost considerations compared to commodity thermoplastics used in injection molding services.
The decision to use EPX 86FR comes down to its unique and valuable combination of properties. It is the material of choice when flame retardancy is a non-negotiable requirement, but you are unwilling to sacrifice mechanical strength, dimensional accuracy, and long-term thermal stability. For intricate parts like connectors, clips, and housings where safety certifications are paramount, EPX 86FR provides a robust solution. Its performance characteristics make it an excellent candidate for producing end-use parts that rival the quality of those made through medical injection molding, while offering greater design freedom. When the application demands a material that can withstand heat, stress, and potential fire exposure, EPX 86FR stands out as a premier option.
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