Rigid Polyurethane 130 (RPU 130) is an engineering-grade material by Carbon used in additive manufacturing, specifically with Carbon's Digital Light Synthesis™ (DLS™) technology. It offers a unique combination of toughness, strength, and high heat resistance, making it suitable for a wide array of demanding functional parts and end-use components across various industries. What sets RPU 130 apart is its ability to produce parts with properties comparable to unfilled thermoplastics like nylon or polypropylene, coupled with a partial bio-based composition for a more sustainable manufacturing approach.
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RPU 130 is engineered to provide a robust set of material properties, making it a versatile option for producing durable parts through additive manufacturing services. Its characteristics are a result of Carbon's innovative dual-cure process, which combines UV curing during printing with a subsequent thermal baking step to achieve final material properties.
RPU 130 exhibits significant strength and toughness, with an ultimate tensile strength of approximately 35 MPa (5 ksi) and a notched Izod impact strength of around 75-76 J/m (1.4 ft-lb/in). This makes it capable of withstanding rigorous use and impacts, suitable for parts that will experience mechanical stress. The material's toughness also contributes to its durability, allowing for the production of resilient components.
A key feature of RPU 130 is its high heat deflection temperature (HDT) of approximately 246°F (119°C) at 0.455 MPa. This thermal stability allows parts made from RPU 130 to maintain their structural integrity and dimensional accuracy even when exposed to elevated temperatures, a critical factor for many automotive and industrial components. It also shows exceptional thermal stability over hundreds of hours at high temperatures.
Parts printed with RPU 130 demonstrate good dimensional stability, meaning they maintain their shape and size under various environmental conditions. The Carbon DLS Prototyping process, for which RPU 130 is designed, is known for producing parts with high accuracy and a great surface finish, which can be crucial for components requiring precise fits or aesthetic appeal. This precision is beneficial in complex assemblies and when replacing parts traditionally made through processes like injection molding.
Addressing the growing demand for more environmentally conscious materials, RPU 130 is composed of approximately 30% Susterra® propanediol, a 100% bio-based polymer building block. This integration of a renewable resource helps reduce the environmental footprint compared to fully petroleum-based polymers without compromising performance.
The robust characteristics of RPU 130 make it suitable for a diverse set of functional parts where durability, heat resistance, and strength are paramount. Its ability to produce parts with fine features and good surface quality also expands its utility.
The automotive industry leverages RPU 130 for various under-the-hood and interior components. Examples include air ducts, brake caliper covers, pipe holder fasteners, and other fixtures that require strength, impact resistance, and the ability to withstand elevated operating temperatures. Its performance can be comparable to unfilled nylon or polypropylene often used in these areas.
RPU 130 is employed in the creation of durable housings for tools and electronic devices, as well as other industrial enclosures and components. These uses benefit from the material's impact resistance, thermal stability, and ability to be formed into complex geometries that might be challenging or costly with traditional manufacturing methods such as injection molding for lower volumes.
For consumer goods, RPU 130 is found in items like eyewear (sunglasses) and key fobs. These items require a blend of toughness for daily handling, good surface aesthetics, and resistance to wear and tear. The material allows for intricate designs that are both functional and visually appealing.
Beyond end-use parts, RPU 130 is also valuable for producing manufacturing aids like jigs and fixtures. Its strength and dimensional stability ensure these tools can withstand repeated use. Furthermore, it's an option for creating high-fidelity functional prototypes that closely mimic the performance of final production parts, including those that might eventually be produced via Low-Volume Injection Molding or other high-volume processes.
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While RPU 130 offers many advantages, there are considerations and potential limitations depending on the specific needs of a project.
RPU 130 exhibits water absorption, with figures around 1.8% in 24 hours and 5.2% over a 14-day period (ASTM D570). For components intended for use in consistently wet or highly humid environments, this moisture uptake could potentially affect dimensional stability or mechanical properties over the long term if not accounted for in the design.
Like many polymers, prolonged exposure to UV radiation can potentially degrade polyurethanes. Carbon's technical data sheet for RPU 130 includes information on UV aging tests (ASTM D4459), implying that this is a factor to consider for outdoor applications or those with significant UV exposure. While the material is engineered for durability, specific performance under extended UV exposure should be evaluated for the intended environment.
RPU 130 is designed exclusively for Carbon's DLS™ additive manufacturing platform. This means that its use is tied to Carbon's hardware, software, and specific processing parameters, including the heated C5 cassette and thermal curing. This differs from materials that can be used across a wider range of open 3D printing systems or traditional manufacturing methods.
Advanced materials and proprietary additive manufacturing processes like Carbon DLS™ can sometimes involve higher per-part costs compared to traditional mass-production methods like injection molding, especially for very high volumes. However, for low to mid-volume production, complex geometries, or rapid iteration, the overall cost-benefit can be favorable by eliminating tooling expenses and reducing lead times.
The coefficient of thermal expansion for RPU 130 is listed as 150 ppm/°C (ASTM E831, -60 to 100 °C). For applications involving large temperature fluctuations or assemblies with materials of vastly different expansion rates, this property needs to be taken into account to prevent stress or fitment issues.
It's important to note that many of these are common considerations for engineered polymers, and RPU 130 is designed to offer a strong balance of properties for many demanding scenarios.
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Choosing RPU 130 offers a compelling combination of mechanical performance, thermal resistance, and design freedom, particularly for complex, durable end-use parts. It stands out as a material that bridges the gap between prototyping and true production-grade components within the additive manufacturing landscape.
Parts produced with RPU 130 using the Carbon DLS™ process exhibit a smooth surface finish and high resolution, often comparable to injection-molded quality. This reduces the need for extensive post-processing and makes it suitable for visible components where aesthetics matter. For those considering materials for medical injection molding, RPU 130 can serve as an excellent material for creating high-fidelity prototypes or even bridge production for devices that require similar durability and surface quality.
RPU 130 is an ideal choice when a project demands strong, heat-resistant, and durable parts with a good surface finish, especially for complex designs or when speed and a degree of sustainability are important factors in the manufacturing process.
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