PPSU FILAMENT • 3DXTECH • REV1 TECH
3DXTech ThermaX™ PPSU Polyphenylsulfone — 220°C Tg · Superior Toughness · Made in USA
Polyphenylsulfone — 220°C Tg · Superior Toughness · Made in USA
3DXTech’s ThermaX PPSU delivers the highest impact toughness of any unfilled ultra-performance filament in the catalog — paired with a 220°C Tg that surpasses ULTEM 1010. Inherently flame resistant (UL 94 V-0), sterilization-capable by all methods (steam, EtO, radiation, plasma), and highly resistant to automotive fluids and gamma radiation. Made in Grand Rapids, Michigan.
Lead time varies. Contact Rev1 to confirm availability.
WHY PPSU
220°C Tg. Highest Toughness. Inherent UL 94 V-0.
ThermaX™ PPSU is 3DXTech’s polyphenylsulfone filament — delivering the highest impact toughness of any unfilled ultra-performance filament in the catalog, inherent UL 94 V-0 flame resistance, and all-method sterilization compatibility.
Highest Impact Toughness
PPSU delivers exceptional toughness and ductility at elevated temperatures — superior impact resistance to PEEK, ULTEM, or any other ultra-performance filament in the catalog.
Inherent UL 94 V-0
Flame resistance is intrinsic to the polyphenylsulfone backbone — no additives. Low smoke evolution makes it suitable for aircraft interior and medical device applications.
All-Method Sterilization
Compatible with steam autoclave (134°C), EtO gas, gamma radiation (up to 10 Mrd), plasma, and dry heat sterilization. One of the most sterilization-versatile filaments available.
Made in USA
Produced in-house at 3DXTech’s Grand Rapids, MI facility under ISO 9001:2015 certification. Lot traceability and process controls throughout.
PRINTING WITH PPSU
PPSU — Polyphenylsulfone for Demanding Applications
ThermaX PPSU is not a plug-and-print material. It requires industrial hardware and process discipline — a heated chamber and all-metal hot end rated to 400°C+. Follow this protocol for consistent results.
- Extruder Temp 360–390°C — all-metal hot end required
- Bed Temp 140–160°C — PEI or garolite build surface
- Chamber Temp ≥70°C recommended — heated enclosure strongly recommended
- Nozzle All-metal, stainless or hardened steel — ≥0.4mm diameter
- Drying 120°C / 4 hr minimum before every print session
- ⚠ End-of-Session Purge nozzle completely before cooling. Residual PPSU can carbonize in the melt zone if left to cool — always purge fully before shutdown.
THERMAL DATA
220°C Tg with the Highest Impact Toughness of Any Unfilled Filament
Four thermal milestones that define ThermaX™ PPSU’s operating envelope — verified against 3DXTech ThermaX PPSU Technical Data Sheet v3.
220°C Tg with the highest impact toughness of any 3DXTech unfilled filament. PPSU maintains structural integrity while absorbing energy where brittle materials fracture — uniquely valuable in medical and chemical process environments.
HDT at 0.45 MPa. Structural load-bearing capability well above standard service temperatures, with hydrolytic stability through repeated autoclave sterilization cycles.
Sustained continuous-use temperature under structural load. For short-term peak exposure, the 207°C HDT and 220°C Tg define the practical upper ceiling.
Required before every session. PPSU is hygroscopic — even trace moisture causes bubble defects and weakened layer adhesion at 360–390°C extrusion temps. Print from the dryer.
CHEMICAL RESISTANCE
High ESCR — Resistant to Chemical Attack Under Stress
ThermaX™ PPSU’s amorphous polyphenylsulfone backbone resists a broad range of chemicals — including automotive fluids, hydrocarbons, alcohols, and aqueous process streams. The sulfone backbone delivers exceptional Environmental Stress Crack Resistance (ESCR), critical when stressed parts contact solvents or cleaning agents.
Consult TDS for complete chemical compatibility data before use in fluid-contact applications.
SPECIFICATIONS
ThermaX™ PPSU — Full Technical Data
Source: 3DXTech ThermaX™ PPSU TDS v3. Specifications at 1.75mm diameter, natural color.
Material Properties
| Polymer | Polyphenylsulfone (PPSU) |
| Diameter | 1.75mm |
| Color | Natural (500g only) |
| Glass Transition (Tg) | 220°C |
| Heat Deflection (HDT) | 207°C |
| Continuous Use Temp | 180°C |
| Flame Rating | UL 94 V-0 (inherent, no additives) |
| Tensile Strength | 72 MPa (ASTM D638) |
| Flexural Strength | 125 MPa (ASTM D790) |
| Tensile Elongation | 15% |
| Density | 1.29 g/cm³ |
Print Parameters
| Extruder Temp | 360–390°C |
| Bed Temp | 140–160°C |
| Chamber Temp | ≥70°C (recommended) |
| Drying Protocol | 120°C / 4 hr minimum |
| Min. Layer Height | 0.10mm |
| Nozzle Type | All-metal (stainless or hardened steel) |
| Min. Nozzle Diameter | 0.4mm |
| Hot End Requirement | All-metal, rated ≥400°C |
Availability & Pricing
| Spool Sizes | 500g (only) |
| Color | Natural (only) |
| 500g Price | $125 |
| Lead Time | Varies — contact Rev1 to confirm |
| Quality Standard | ISO 9001:2015 Certified |
| Origin | Grand Rapids, MI, USA |
SPOOL SELECTION
500g Natural — Single Spool Configuration.
ThermaX™ PPSU is available in 500g natural only. For custom color or volume requirements, contact Rev1 Tech for availability.
- Reel #2–#7 — 198mm dia.
- Color: Natural
- Ultra-performance polyphenylsulfone
PRINT QUALITY
Production-Grade Output on the Right Equipment
ThermaX™ PPSU produces parts with excellent surface detail and strong interlayer adhesion when printed on a properly configured industrial platform with an all-metal hot end and heated chamber.
COMPATIBLE PLATFORMS
Requires an Industrial-Grade 3D Printer
ThermaX™ PPSU demands an all-metal hot end rated to at least 400°C and an actively heated enclosure (≥70°C). Beyond consumer hardware, but accessible to any purpose-built industrial platform.
CreatBot F160-PEEK
Purpose-built PAEK platform with dual all-metal hot ends and integrated chamber heating. Validated for PPSU and PEEK — Rev1’s top recommendation for first-time ultra-performance adopters.
Rev1 RecommendedCreatBot PEEK-300
300mm build volume, 420°C hot end rating, 200°C heated chamber. Production-oriented PAEK platform suitable for PPSU at larger part geometries.
Rev1 RecommendedCreatBot F430
Quad-nozzle large-format industrial printer with multi-material capability. Supports PPSU plus support materials for complex geometries and dual-extrusion workflows.
Rev1 RecommendedAny Open-Platform Printer
Minimum: 400°C+ all-metal hot end • 120–160°C heated bed • ≥70°C enclosure • all-metal nozzle ≥0.4mm.
WHERE IT WORKS
Six Industries Where Toughness, Sterilization, and Flame Resistance Converge
When impact toughness, all-method sterilization, inherent UL 94 V-0, and a 220°C Tg must coexist — ThermaX™ PPSU is the answer.
Aerospace
Structural brackets, ducting, aircraft interior components requiring FAR 25.853 flammability compliance, low smoke, and high-impact toughness.
Medical
Surgical instrument handles, reusable device components, fixture tooling, and housings requiring all-method sterilization compatibility including steam autoclave at 134°C.
Chemical Processing
Pump housings, valve bodies, manifolds, and impeller components exposed to aggressive chemical process streams at elevated temperatures. High ESCR (Environmental Stress Crack Resistance).
Automotive
Under-hood fluid-contact components, brackets, and sensor housings resistant to gasoline, antifreeze, transmission fluids, motor oils, and power steering fluid.
Nuclear / Radiation
Instrumentation housings, fixture tooling, and structural components in environments with gamma radiation exposure up to 10 Mrd doses.
Electronics
Stable dielectric properties, inherent flame resistance, and high thermal capability for power electronics housings and EMI shielding structures.
MATERIAL CARE
Moisture Is the Enemy. A Proper Protocol Eliminates It.
PPSU is hygroscopic and absorbs moisture readily. Printing with undried filament at 360–390°C produces bubbling, rough surfaces, and weakened layer adhesion. Follow this protocol every session.
Dry Before Every Session
120°C minimum / 4 hours minimum. No exceptions — even a sealed spool that has been open for a few days benefits from a fresh drying cycle.
Print From the Dryer
For best results, print directly from a heated dry-box or dryer system. Ambient humidity will re-absorb into the filament during extended print runs.
Store Sealed With Desiccant
Return unused filament to an airtight bag or container with fresh desiccant immediately after printing. Long-term storage in original sealed packaging is acceptable.
Recognize Wet Filament Symptoms
Popping or crackling during extrusion, rough surface texture, reduced layer adhesion, and visible bubbling in the melt are signs of moisture contamination. Re-dry and restart.
HOW IT COMPARES
ThermaX™ PPSU vs. Commonly Evaluated Alternatives
Buyers evaluating PPSU typically compare against ThermaX PSU for a lower-temperature sulfone option, ThermaX PEI 1010 for a similarly-rated flame-resistant material, and ThermaX PEEK for maximum stiffness.
3DXTech / Rev1 Tech
3DXTech
3DXTech
3DXTech
3DXTECH QUALITY
Manufactured in Michigan. Certified to ISO 9001:2015.
Every spool of ThermaX™ PPSU is produced in-house at 3DXTech’s Grand Rapids, MI facility under ISO 9001:2015 certification. Polyphenylsulfone resin with inherent UL 94 V-0 and full lot traceability throughout filament fabrication.
ISO 9001:2015 Certified
Production under a certified quality management system. Lot traceability and process controls throughout filament fabrication.
Made in Grand Rapids, MI
Filament extruded and wound in-house at 3DXTech’s Michigan facility. Direct factory quality control — not overseas commodity production.
Technical Data Sheet Available
Full processing parameters, mechanical properties, UL 94 V-0 compliance data, and chemical resistance published in the ThermaX™ PPSU TDS v3. Available for download below.
RESOURCES
Downloads & Technical Support
Everything you need to qualify and print ThermaX™ PPSU with confidence. UL 94 V-0 compliance data, processing parameters, and technical support from Rev1.
WHY REV1 TECH
Authorized 3DXTech Reseller. Industrial AM Specialists.
Rev1 Technologies is an authorized 3DXTech reseller headquartered in Auburn Hills, MI, with direct technical expertise in high-performance FFF materials and the printers that run them.
Authorized Reseller
Every spool ships direct from the authorized channel. MAP pricing guaranteed. Single-channel license compliance — not a grey-market distributor.
Platform Expertise
Rev1 carries the industrial printers validated for PPSU and PEEK. If you need guidance on which platform to match with this material, our team has run them.
Pre-Sales Technical Support
Questions about print settings, printer selection, or qualifying PPSU for a specific application? Contact Rev1 before you order — that conversation is free.
FREQUENTLY ASKED
ThermaX™ PPSU — Buyer & Engineer Questions Answered
What is ThermaX PPSU?
ThermaX PPSU is 3DXTech’s polyphenylsulfone filament — an amorphous high-performance thermoplastic with a 220°C Tg, inherent UL 94 V-0 flame resistance, and the highest impact toughness of any unfilled ultra-performance filament in the catalog. It is compatible with all major sterilization methods including steam autoclave.
What temperatures does ThermaX PPSU require?
Extruder: 360–390°C with an all-metal hotend. Bed: 140–160°C on PEI or garolite. Heated chamber (≥70°C) is strongly recommended. Dry at 120°C for 4 hours before printing.
Why is PPSU used for medical sterilization applications?
PPSU is compatible with steam autoclave (134°C), ethylene oxide (EtO), gamma radiation (up to 10 Mrd), plasma, and dry heat sterilization — making it uniquely versatile among high-performance filaments. Its 220°C Tg ensures dimensional stability through steam cycles, and its superior hydrolytic stability means repeated autoclave cycles do not degrade mechanical properties as they would in many competing materials.
What is the difference between PPSU and PEI 1010 (ULTEM 1010)?
Both have similar Tg values (~220°C vs 217°C) and both are inherently flame resistant. The key difference is impact toughness: PPSU is significantly tougher and more ductile than ULTEM 1010, making it the better choice when parts must absorb impact loads. PPSU also supports all sterilization methods, while ULTEM 1010 is specifically FDA-compliant and the better choice for food contact.
What is ESCR and why does PPSU have it?
Environmental Stress Crack Resistance (ESCR) is the ability of a polymer to resist crack initiation and propagation when simultaneously under mechanical stress and chemical exposure. PPSU’s ductile amorphous structure and sulfone backbone deliver high ESCR — critical in chemical processing applications where solvents or cleaning agents contact stressed parts.
Why is PPSU only available in 500g natural?
ThermaX PPSU is a specialty ultra-performance material with lower overall demand than PEI or PEEK grades, and the natural color is the standard production form. For custom color needs or volume requirements, contact Rev1 Tech for availability.
How does ThermaX PPSU compare to Stratasys FDM PPSU?
Both use polyphenylsulfone resin. Stratasys FDM PPSU is platform-locked to Fortus systems with soluble support requirements and high platform cost. ThermaX PPSU runs on any open-material machine capable of 360–390°C with a heated chamber — the same amorphous sulfone chemistry at a fraction of the system cost.
Should I choose PPSU or ThermaX PEEK for a medical device part?
Choose PPSU for parts requiring all-method sterilization (especially repeated steam autoclave cycles), high impact toughness, or when the application involves chemical exposure during use (ESCR). Choose PEEK for maximum stiffness and tensile strength, or when biocompatibility to ISO 10993 is required — PEEK is the established biocompatible standard for implant and implant-adjacent applications.