Some help/guidance regarding picking the correct Zortrax material

hi!

Im in a racecar project and we’re printing our rear wing for the car. 

It will be 12 parts roughly 220mm tall and the wing profile is 160mm x 40mm roughly. I’ve done a lot of testing with Colorfabb Ngen which seems strong yet flexible enough, and it can withstand the heat that these wings will be put up against a hot summer day at the track. 

We need a glass transition temp of about 80-100 degrees I think.

Im getting my M300 today! (yay), and I will print some wings as a first test, I will fill up the build volume so it’s important that I also pick a material that will print as good as possible, making sure that the risk of failure is as low as possible. 

I’ve had some issues with layer splitting even with NGEN before I fine tuned the cooling and temperatures (this was with an open air printer though).

What material would you recommend out of Zortrax library? 

What I can find looking through all the Data Sheets its only the new Z-PLA which wouldn’t manage heat wise.

The new Z-ASA Pro has an advantage because of the UV resistance.

The PETG + ULTRAT would probably work out as well, and maybe ABS, although Im a bit afraid when it comes to shrinkage and warping here since the wing profiles has a pretty long base onto the buildplate.

Any tips? 

Here is a short video regarding the wings!

https://www.youtube.com/watch?v=xFatDaQLczI

since that was recorded, we’ve decided to divide the wings in shorter parts, and there will be two carbon tubes running through the wings which they also will be glued onto.

Best Regards Patrik

 

ABS, Ultrat and PC-ABS should be fine <120*C, last one is no-go due to its warping though. PETG / GLASS are getting 'soft' <100*C. ASA Pro also should do the trick.

Perhaps another solution here :

Use Z Suite v1,11 + external materials + PLA based filament.

 

Print with the BIG REP PLA PRO HT (https://bigrep.com/shop/filament/high-temperature-filament-abs-alternative/) that resists 115 ° and also resists outside. Only in black !

 

The filament prints very well on any printer with hot plate !

Ultrat or ASA Pro seems like a good choice then! 

@axel I’ll start using Zortrax filaments for now, I got this printer as my printer number 6 and since I need a very constant and reliable printer. 

using external filaments will probably work as well but I want to spend minimal of time adjusting and fine tuning when using the M300…  I have to do that with my other printers :smiley:

What about hips? around 80 degrees C?

Its installed! :smiley:

Ultrat or ASA Pro seems like a good choice then! 

@axel I’ll start using Zortrax filaments for now, I got this printer as my printer number 6 and since I need a very constant and reliable printer. 

using external filaments will probably work as well but I want to spend minimal of time adjusting and fine tuning when using the M300…  I have to do that with my other printers :smiley:

What about hips? around 80 degrees C?

Its installed! :smiley:

Hips got similar resistance as ABS&Ultrat, so it should be fine as well. 

Hips got similar resistance as ABS&Ultrat, so it should be fine as well. 

Printing my first Zortrax print now! 92% through, using the HIPS spool that came with the printer.

I’ll decide if I should use HIPS or ULTRAT for the wings, needs to print them this week :) 

Which of the Z-Materials would be considered free of fumes/smells? I’m sitting next to my printer, and after the summer I’ll move into an office space/studio with my business, and I cant really print ABS because of the smell, if I dont create a “lid” to place on top of the printer with some HEPA/CARBON filters.

 

What are the main reason for NOT using HIPS for our rear wings? 

I did a test with Z-Tool and ULTRAT but got a nozzle clog half way through, I just want to stick to Z-Suite and not fiddle around, I’m doing that with all my other printers and I really want the M300 to be a workhorse, even though I’ll be limited in some ways.

The HIPS has printed well for 4 prints now and no problems printing 0.29mm layers, (my upcoming prints are LARGE) so I need as high layers as possible. Although HIPS is not UV resistant, although how bad can it be you think?

 

What are the main reason for NOT using HIPS for our rear wings? 

I did a test with Z-Tool and ULTRAT but got a nozzle clog half way through, I just want to stick to Z-Suite and not fiddle around, I’m doing that with all my other printers and I really want the M300 to be a workhorse, even though I’ll be limited in some ways.

The HIPS has printed well for 4 prints now and no problems printing 0.29mm layers, (my upcoming prints are LARGE) so I need as high layers as possible. Although HIPS is not UV resistant, although how bad can it be you think?

 

There isn't any, except maybe lack of UV resistance, but since PLA Pro & ASA Pro arent wont be able to 'work' in high temperatures, maybe you should consider using some kind of UV Coating? We haven't tested it so I wont be any reliable source of feedback

There isn't any, except maybe lack of UV resistance, but since PLA Pro & ASA Pro arent wont be able to 'work' in high temperatures, maybe you should consider using some kind of UV Coating? We haven't tested it so I wont be any reliable source of feedback

yeah some UV coating spray is already ordered for testing! I've also ordered a 2 kilo HIPS spool in black even though it will make the wing warmer in the sun indeed...the customer wants black wings though, and the customer is always right huh? 

If the wing breaks because of UV, we’ll have time to reprint new ones during the winter I think, the car will race 3-4 times this summer, and between the races it will stand in the shade anyway, so I think the HIPS will manage!