FDM TechnologyThermoplastic

The Ultimate High-Performance ThermoplasticHighest Heat Resistance, Chemical Resistance & Tensile Strength of Any FDM Material

ULTEM 1010 is a high-performance polyetherimide resin with exceptional heat resistance, tensile strength, dimensional stability, and chemical resistance. Its thermal stability and mechanical properties make it an excellent choice for high-performance prototyping, tooling, and production parts that will be exposed to high temperatures. The availability of a certified grade expands its applications to include biocompatible and food contact applications. ULTEM 1010's versatility and reliability make it a preferred material for industries seeking robust solutions that can withstand demanding environments.

Tensile Strength
N/A
Flexural Modulus
2,820 MPa
Temperature Resistance
216 °C
Technology
FDM
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ULTEM 1010 3D printed part example
Large Build Volume
Cost-Effective
FDM material

ULTEM 1010 overview

ULTEM 1010 is a high-performance polyetherimide (PEI) resin that represents the pinnacle of FDM thermoplastic performance. With the highest heat resistance, chemical resistance, and tensile strength of any FDM material, ULTEM 1010 excels in the most demanding applications. Its exceptional thermal stability with a glass transition temperature of 215°C, combined with superior mechanical properties and broad chemical compatibility, makes it the material of choice for aerospace, medical, and high-performance manufacturing applications. The availability of certified grades meeting NSF 51 and USP Class VI standards expands its use to biocompatible and food contact applications.

Why manufacture with ULTEM 1010

ULTEM 1010 combines highest heat resistance of any fdm thermoplastic (215°c tg) and exceptional tensile strength up to 81 mpa in optimal orientation, delivering superior chemical resistance to wide range of industrial chemicals for demanding applications. From rapid prototyping to production runs, teams rely on ULTEM 1010 to maintain tight tolerances while reducing assembly complexity through consolidated part designs.

FDM Production Technology

ULTEM 1010 achieves the highest thermal performance in FDM technology with 216°C heat deflection temperature and unmatched chemical resistance, certified for food and biocompatibility applications. The Stratasys Fortus 900mc's extreme temperature capability (400°C extrusion) ensures optimal PEI molecular alignment, delivering 81 MPa tensile strength and 2,820 MPa modulus. With NSF 51 food contact and ISO 10993 biocompatibility certifications, ULTEM 1010 produces autoclave-resistant medical instruments and food processing equipment. The material's resistance to automotive fluids, cleaning chemicals, and steam sterilization makes it irreplaceable for applications demanding both extreme performance and regulatory compliance.

Build Volume

914 × 610 × 914 mm (36 × 24 × 36 in)

Max part size

Lead Time

2-4 business days

Fast turnaround available

Layer Height

0.127 mm (0.005 in) to 0.330 mm (0.013 in)

Resolution

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Manufactured in Forge Labs' North American production centers with serialized traceability for ULTEM 1010.

ULTEM 1010 FDM cube sample showing high-performance thermoplastic properties
Technical resources

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Technical datasheet

Detailed specs for ULTEM 1010.

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Applications & field work

Where ULTEM 1010 excels

ULTEM 1010 represents the apex of FDM thermoplastic performance, with the highest heat resistance (215°C Tg), chemical resistance, and tensile strength available in additive manufacturing. This exceptional combination enables applications from autoclave tooling to biocompatible medical devices.

The material's NSF 51 food contact certification and USP Class VI biocompatibility open doors to regulated industries where material safety is paramount. Combined with resistance to gamma radiation, EtO, and steam sterilization, ULTEM 1010 serves applications from surgical instruments to food processing equipment.

With Forge Labs' temperature-controlled Fortus systems maintaining ±2°C chamber stability, ULTEM 1010 delivers consistent mechanical properties that rival injection molding. Our certified grade material with lot traceability ensures every part meets the stringent requirements of aerospace, medical, and food industries.

Mechanical
Tensile Strength, Ultimate (XZ Axis): 81 MPa
ASTM D638 - 81 MPa tensile strength
Thermal
Heat Deflection Temperature @ 0.45 MPa: 216 °C
HDT 216°C @ 0.45 MPa
Physical
Density: 1.29 g/cm³
Electrical
Volume Resistivity: >7.0×10¹⁴ Ω·cm
FDM applications showcase
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Industry applications for ULTEM 1010

From composite tooling to surgical instruments, ULTEM 1010 enables innovation in the most demanding applications. Discover how industry leaders leverage this premium material.

ULTEM 1010's ability to withstand 180°C autoclave cycles makes it the premier choice for composite tooling. The material maintains dimensional stability through repeated cure cycles, enabling cost-effective tooling for aerospace composites.

Key Applications

  • Autoclave-capable composite lay-up tools
  • Vacuum bagging mandrels and caul plates
  • Trim and drill fixtures for cured composites
  • Bonding jigs for aerospace assemblies

Performance Data

Maintains ±0.2% dimensional accuracy through 50+ autoclave cycles at 180°C/100 psi, with <0.5% moisture absorption preventing tool degradation.

ULTEM 1010's USP Class VI biocompatibility and sterilization resistance enable direct-use medical applications. The material withstands repeated autoclave sterilization while maintaining mechanical properties critical for surgical instruments.

Key Applications

  • Custom surgical guides and templates
  • Sterilizable instrument trays and organizers
  • Specialized surgical tool handles
  • Medical device prototypes for FDA submission

Performance Data

Survives 100+ steam autoclave cycles at 134°C with <2% change in mechanical properties, meeting ISO 10993 biocompatibility standards.

Explore surgical & medical instruments

NSF 51 certification enables ULTEM 1010 for direct food contact applications where high temperature and chemical resistance are required. The material's smooth surface finish prevents bacterial growth while withstanding industrial cleaning protocols.

Key Applications

  • Custom food processing fixtures and molds
  • High-temperature conveyor components
  • Specialized packaging equipment parts
  • Beverage dispensing system components

Performance Data

Withstands CIP/SIP cleaning at 150°C with caustic solutions (pH 12+), maintaining NSF 51 compliance through 500+ wash cycles.

ULTEM 1010 enables manufacturing fixtures and tooling that survive extreme thermal cycling and chemical exposure. The material's strength at temperature allows functional tooling for processes impossible with standard thermoplastics.

Key Applications

  • High-temperature assembly fixtures
  • Chemical processing equipment components
  • Thermal forming dies and molds
  • Test fixtures for environmental chambers

Performance Data

Maintains 75% room temperature strength at 170°C continuous use, with resistance to 150+ industrial chemicals including acids and solvents.

Explore high-temperature manufacturing

ULTEM 1010 production examples

FDM applications showcase

FDM applications showcase

Industrial FDM Applications

ULTEM 1010 automotive intake manifold demonstrating high heat resistance

ULTEM 1010 automotive intake manifold demonstrating high heat resistance

Automotive Intake

Aerospace wing component made with ULTEM 1010

Aerospace wing component made with ULTEM 1010

Aerospace Wing Part

Performance Dashboard

Technical performance for ULTEM 1010

ULTEM 1010 delivers dependable strength and impact resistance for Composite lay-up tooling and autoclave-capable molds and Medical surgical guides and sterilizable instrument trays, helping teams move from prototype to production with confidence.

Mechanical Properties

Tensile Strength, Ultimate (XZ Axis)

81 MPa

ULTEM 1010 records Tensile Strength, Ultimate (XZ Axis) at 81 MPa, reinforcing its mechanical properties story.

Mechanical Properties

Tensile Strength, Ultimate (ZX Axis)

37 MPa

ULTEM 1010 records Tensile Strength, Ultimate (ZX Axis) at 37 MPa, reinforcing its mechanical properties story.

Mechanical Properties

Tensile Strength, Yield (XZ Axis)

64 MPa

ULTEM 1010 records Tensile Strength, Yield (XZ Axis) at 64 MPa, reinforcing its mechanical properties story.

ULTEM 1010 combines Highest heat resistance of any FDM thermoplastic (215°C Tg) and Exceptional tensile strength up to 81 MPa in optimal orientation to support Composite lay-up tooling and autoclave-capable molds and Medical surgical guides and sterilizable instrument trays that demand production-ready durability.

Measurement
ULTEM 1010Base
Standard
Tensile Strength, Ultimate (XZ Axis)81 MPa—
Tensile Strength, Ultimate (ZX Axis)37 MPa—
Tensile Strength, Yield (XZ Axis)64 MPa—
Tensile Strength, Yield (ZX Axis)42 MPa—
Elongation at Break3.3 %—
Tensile Modulus (XZ Axis)2,770 MPa—
Tensile Modulus (ZX Axis)2,200 MPa—
Flexural Strength (XZ Axis)144 MPa—
Flexural Strength (ZX Axis)77 MPa—
Flexural Modulus (XZ Axis)2,820 MPa—
Flexural Modulus (ZX Axis)2,230 MPa—
Impact Strength, Notched (XZ Axis)41 J/m—
Impact Strength, Notched (ZX Axis)24 J/m—
Impact Strength, Unnotched (XZ Axis)326 J/m—
Impact Strength, Unnotched (ZX Axis)138 J/m—
Compressive Strength, Yield (XZ Axis)134 MPa—
Compressive Strength, Yield (ZX Axis)107 MPa—
Compressive Modulus (XZ Axis)10,000 MPa—
Compressive Modulus (ZX Axis)1,120 MPa—
Mechanical Performance

Mechanical Properties

ULTEM 1010 delivers dependable strength and impact resistance for Composite lay-up tooling and autoclave-capable molds and Medical surgical guides and sterilizable instrument trays, helping teams move from prototype to production with confidence.

ULTEM 1010 delivers exceptional mechanical performance with excellent strength characteristics, effectively handling demanding load conditions. Its balanced mechanical profile allows it to maintain structural integrity while preventing brittleness in critical applications.

These qualities make it well-suited for Composite lay-up tooling and autoclave-capable molds, Medical surgical guides and sterilizable instrument trays, and Aerospace structural components and high-temp ducting, providing long-term durability in demanding environments. ULTEM 1010 maintains dimensional stability over time, ensuring consistent performance across temperature and stress variations.

This makes it a reliable choice for applications requiring precise geometries and tight tolerances across Aerospace, Medical Device, and Automotive. Its versatility and durability allow it to perform consistently across a wide range of mechanical applications, ensuring parts maintain their integrity under repetitive stress and environmental conditions.

ULTEM 1010 combines Highest heat resistance of any FDM thermoplastic (215°C Tg) and Exceptional tensile strength up to 81 MPa in optimal orientation to support Composite lay-up tooling and autoclave-capable molds and Medical surgical guides and sterilizable instrument trays that demand production-ready durability.

Key metric

Tensile Strength, Ultimate (XZ Axis)

81 MPa

Key metric

Tensile Strength, Ultimate (ZX Axis)

37 MPa

Key metric

Tensile Strength, Yield (XZ Axis)

64 MPa

Dive into the data

Detailed mechanical measurements live in the performance dashboard above. Switch tabs to compare against other materials instantly.

Material Makeup

Physical Properties

ULTEM 1010 offers consistent density and surface quality so critical features hold tolerances and downstream finishing remains predictable.

ULTEM 1010 exhibits a density of 1.29 g/cm³ that contributes to lightweight yet durable parts. With moisture absorption of 0.25 %, ensures dimensional stability in varying environmental conditions.

These physical properties enable consistent part quality and predictable performance across Composite lay-up tooling and autoclave-capable molds, Medical surgical guides and sterilizable instrument trays, and Aerospace structural components and high-temp ducting. The material's inherent characteristics minimize warpage and maintain tight tolerances throughout the part lifecycle.

For Aerospace, Medical Device, and Automotive, these physical attributes translate to reliable production outcomes with minimal post-processing requirements, ensuring parts meet specifications straight from the build platform.

ULTEM 1010 delivers 1.29 g/cm³ density so assemblies fit and finish without secondary rework.

Key metric

Density

1.29 g/cm³

Key metric

Water Absorption (24 hours)

0.25 %

Key metric

Water Absorption (Saturated)

1.25 %

Dive into the data

Detailed physical properties measurements live in the performance dashboard above. Switch tabs to compare against other materials instantly.

Heat Performance

Thermal Properties

ULTEM 1010 maintains dimensional stability through temperature swings, making it a reliable option for Aerospace and Medical Device programs that see repeated thermal cycling.

ULTEM 1010 demonstrates excellent thermal stability with a heat deflection temperature of 216 °C, enabling it to maintain dimensional accuracy in elevated temperature environments. This thermal performance ensures parts retain their shape and mechanical properties even under thermal stress.

The material's thermal characteristics make it ideal for Composite lay-up tooling and autoclave-capable molds, Medical surgical guides and sterilizable instrument trays, and Aerospace structural components and high-temp ducting that experience temperature fluctuations. Its ability to withstand thermal cycling without degradation ensures long-term reliability in Aerospace, Medical Device, and Automotive.

With an operating temperature range up to 170 °C, ULTEM 1010 provides engineers with confidence when designing parts for thermally demanding applications, from under-hood automotive components to industrial equipment exposed to heat sources.

ULTEM 1010 maintains geometry with a Heat Deflection Temperature @ 0.45 MPa of 216 °C, protecting dimensional integrity during heat cycling.

Key metric

Heat Deflection Temperature @ 0.45 MPa

216 °C

Key metric

Heat Deflection Temperature @ 1.8 MPa

213 °C

Key metric

Glass Transition Temperature

215 °C

Dive into the data

Detailed thermal properties measurements live in the performance dashboard above. Switch tabs to compare against other materials instantly.

Functional Performance

Electrical Properties

ULTEM 1010 provides predictable electrical behavior for housings and functional prototypes that need controlled resistivity and dielectric strength.

ULTEM 1010 provides controlled electrical resistivity of >7.0×10¹⁴ Ω·cm, making it suitable for electrical housings and insulators. Its dielectric strength of 32.7 kV/mm ensure reliable performance in electrical assemblies.

These electrical characteristics enable its use in Composite lay-up tooling and autoclave-capable molds, Medical surgical guides and sterilizable instrument trays, and Aerospace structural components and high-temp ducting where electrical performance is critical. The material maintains consistent electrical properties across its operating temperature range, ensuring stable performance in varying conditions.

For Aerospace, Medical Device, and Automotive requiring precise electrical behavior, ULTEM 1010 delivers the consistency and reliability needed for functional prototypes and production parts that interact with electrical systems.

ULTEM 1010 posts >7.0×10¹⁴ Ω·cm Volume Resistivity, giving enclosures dependable insulating performance.

Key metric

Volume Resistivity

>7.0×10¹⁴ Ω·cm

Key metric

Dielectric Constant @ 1 kHz

2.841

Key metric

Dielectric Constant @ 2 MHz

3.089

Dive into the data

Detailed electrical properties measurements live in the performance dashboard above. Switch tabs to compare against other materials instantly.

Compatibility Data

Chemical Properties

ULTEM 1010 offers tested chemical resistance across acids, bases, solvents, and hydrocarbons to ensure reliable performance in harsh environments.

ULTEM 1010 demonstrates broad chemical resistance with testing against 12 different chemicals, showing excellent compatibility with 5 substances and good compatibility with 4 others. This extensive chemical resistance profile makes it suitable for harsh industrial environments.

The material's resistance to acids, bases, solvents, and hydrocarbons enables its use in Composite lay-up tooling and autoclave-capable molds, Medical surgical guides and sterilizable instrument trays, and Aerospace structural components and high-temp ducting that require exposure to aggressive chemicals. Its chemical inertness ensures parts maintain their mechanical properties even after prolonged chemical exposure.

For Aerospace, Medical Device, and Automotive, this chemical stability translates to longer service life and reduced maintenance requirements, making ULTEM 1010 a cost-effective choice for chemically demanding applications.

ULTEM 1010 has been tested against 12 chemicals with 5 showing excellent compatibility for demanding chemical environments.

Key metric

Automotive Fluids

Excellent

Type: Hydrocarbon

Key metric

Fully Halogenated Hydrocarbons

Excellent

Type: Hydrocarbon

Key metric

Alcohols

Excellent

Type: Solvent

Dive into the data

Detailed chemical properties measurements live in the performance dashboard above. Switch tabs to compare against other materials instantly.

Chemical Resistance

Chemical compatibility for ULTEM 1010

Evaluate how ULTEM 1010 responds to common chemicals before you commit to production tooling. Filter the grid to focus on acids, bases, solvents, or hydrocarbons.

12 of 12 chemicals shown

ChemicalTypeCompatibility
Automotive FluidsHydrocarbonExcellent
Fully Halogenated HydrocarbonsHydrocarbonExcellent
AlcoholsSolventExcellent
Aqueous SolutionsSalt SolutionExcellent
Cleaning AgentsSolventExcellent
Mineral OilsHydrocarbonGood
Weak AcidsAcidGood
Weak BasesBaseGood
Aliphatic HydrocarbonsHydrocarbonGood
Strong AcidsAcidPoor
Strong BasesBasePoor
KetonesSolventPoor
Medical Readiness

Biocompatibility and compliance profile

ULTEM 1010 meets key medical standards so teams can accelerate regulatory reviews and develop parts with short-term contact requirements.

Compliance standards

Download certificates to include with quality documentation or share with your QA team.

StandardCertifiedNotes
UL 94 V-0CertifiedFlame retardancy rating for electrical components
NSF 51 Food ContactCertifiedFood contact surface certification (Certified Grade)
ISO 10993/USP Class VICertifiedBiocompatibility for medical devices (Certified Grade)
ASTM E595 OutgassingCertifiedLow outgassing for space applications
FAR 25.853CertifiedFederal Aviation Regulation compliance
RoHSCertifiedRestriction of Hazardous Substances Directive

Medical-ready programs

Common applications our medical customers pursue with ULTEM 1010.

  • Medical surgical guides and sterilizable instrument trays
Resources

Datasheets and design resources

Equip your team with certification packs, design guides, and spec sheets tailored to ULTEM 1010.

Download center

Access the most recent datasheet and supporting documentation maintained by our engineering team.

Resources

Material DatasheetMechanical Properties Overview

Design guidelines

Explore printable geometry recommendations, wall thickness tips, and finishing playbooks for FDM.

View FDM design guide

Compliance certificates

Keep your quality packet current with pre-approved certifications.

UL 94 V-0Certified
NSF 51 Food ContactCertified
ISO 10993/USP Class VICertified

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Advanced Manufacturing

Built with Precision FDM Technology

ULTEM 1010 is manufactured using Fused Deposition Modeling (FDM) technology, offering reliable performance for functional prototypes and end-use parts.

FDM Manufacturing Lab

ULTEM 1010 runs on industrial FDM platforms with heated chambers, hardened extrusion paths, and qualified material profiles to guarantee consistent layer adhesion and mechanical integrity.

Process Parameters

Layer Height
0.127 mm (0.005 in) to 0.330 mm (0.013 in)
Tolerance
± 0.127 mm (± 0.005 in) or ± 0.15%, whichever is greater
  • Build Volume: 914 × 610 × 914 mm (36 × 24 × 36 in). Large production capacity enables efficient manufacturing of multiple parts or assemblies.
  • Quality Control. In-process monitoring and batch traceability ensure consistent part quality and material properties.

Finishing Options

Support removalMachiningSandingDrillingTappingVapor polishingAutoclave sterilization
Learn more about FDM Technology
Frequently Asked Questions

Frequently asked questions about ULTEM 1010

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ULTEM 1010 is known for its highest heat resistance of any fdm thermoplastic (215°c tg), exceptional tensile strength up to 81 mpa in optimal orientation, superior chemical resistance to wide range of industrial chemicals, making it suitable for aerospace and medical device applications.

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