Aerospace
Out-of-Cabin Parts & Composite Tooling
Out-of-cabin parts, MRO fixtures and lay-up tools that withstand 177 °C autoclave cycles.
Fused Deposition Modeling ULTEM 1010 For High-Heat Tooling and Harsh Environments
Large Build Volume
Up to 914 × 610 × 914 mm
FDM material
ULTEM 1010 overview
ULTEM 1010 is the most heat-resistant plastic for FDM 3D printing, for tools and parts that must stay strong when hot. Parts keep their shape in hot engine bays and autoclave cycles, resist fuels, coolants and many industrial chemicals, and are naturally flame retardant. Its certified grade is approved for food contact and meets medical biocompatibility standards, and surgical guides made from it can be steam sterilized. Aerospace, automotive, medical and food production teams use it for composite lay-up tools, under-hood ducts and housings, surgical guides, instrument trays and food-production fixtures.
How ULTEM 1010 is manufactured
ULTEM 1010 is manufactured using Fused Deposition Modeling (FDM) on Stratasys Fortus production systems, which build parts layer by layer from PEI filament, with no tooling. Large build envelopes take full-size tools, ducts and fixtures in one piece. This makes ULTEM 1010 a practical route to autoclave-resistant medical instruments, composite tooling and food-production fixtures, in quantities from a single tool to low-volume production.
- Build volume
- 914 × 610 × 914 mm
- Lead time
- 2-4 business days
- Layer height
- 0.254-0.330 mm
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Industry applications
Industry applications for ULTEM 1010
ULTEM 1010 combines exceptional tensile strength along the layers with resistance to a wide range of fuels, coolants and industrial chemicals, and keeps its shape under load above 200 °C, a combination that enables applications from autoclave tooling to biocompatible medical devices.
The certified grade's food-contact and biocompatibility approvals open doors to regulated industries where material safety is paramount. Combined with resistance to steam autoclaving, ULTEM 1010 serves applications from surgical instruments to food production, where it makes temperature-resistant dies, patterns and fixtures, high-temperature conveyor and packaging equipment parts and beverage-dispensing components.
From rapid prototyping to production runs, teams rely on ULTEM 1010 to maintain tight tolerances while reducing assembly complexity through consolidated part designs. Forge Labs' Fortus systems deliver consistent, repeatable mechanical properties, and a Stratasys certificate of conformity traces every material lot, giving aerospace, medical and food programs the documentation they ask for.
Flame retardant, low-outgassing and electrically insulating, ULTEM 1010 also serves vacuum and space hardware, semiconductor manufacturing fixtures, and hot-zone parts and insulating components in power and electrical equipment. Its heat resistance and dimensional stability suit test fixtures for environmental chambers, laboratory and chemical processing components, and precision metrology fixtures and gauges.
Automotive
Under-Hood Ducting & Hot-Zone Parts
Under-hood ducts and housings with excellent resistance to fuels and engine coolant.
Medical & Healthcare
Surgical Guides & Sterilizable Instrument Trays
Surgical guides and instrument trays in a USP Class VI material that withstands autoclaving.
Aerospace
Out-of-Cabin Parts & Composite Tooling
Aerospace and defense teams use ULTEM 1010 for out-of-cabin and high-heat parts, MRO jigs and fixtures, and composite tooling: lay-up tools, caul plates, vacuum-bagging mandrels, bonding jigs and trim and drill fixtures. Printed lay-up tools withstand autoclave cures at 177 °C and 100 psig and last up to 50 cure cycles, as many as 100 on some tools, without the lead time of a machined metal tool.
- Out-of-cabin and high-heat parts
- MRO jigs and fixtures
- Composite lay-up and trim tools
Automotive
Under-Hood Ducting & Hot-Zone Parts
Automotive teams turn to ULTEM 1010 where nylon's heat resistance is not enough: under-hood housings, ducts and semi-structural components, sensor housings and heat shields. It has excellent resistance to petroleum fuels and engine coolant. For cab ducts that carry heated air from the heater core, ULTEM 1010 is the higher-temperature option when PA12 grades do not suit the operating conditions, and the same material makes assembly fixtures for hot production steps.
- Under-hood housings and ducts
- Sensor housings and heat shields
- Hot-zone assembly fixtures
Medical & Healthcare
Surgical Guides & Sterilizable Instrument Trays
Medical device teams use ULTEM 1010 for patient-specific surgical guides, sterilizable instrument trays and organizers, surgical tool handles and device prototypes for regulatory testing. The certified grade meets ISO 10993 and USP Class VI, and surgical guides made from it withstand steam autoclaving. Forge Labs inspects every medical part and post-processes and packs it in a cleanroom.
- Patient-specific surgical guides
- Sterilizable instrument trays
- Surgical tool handles
Performance data
Technical performance for ULTEM 1010
Values from the Stratasys ULTEM 1010 resin datasheet, with mechanical properties printed on a Stratasys F900, tested to the standard listed with each property.
Mechanical performance
Mechanical properties
ULTEM 1010 delivers dependable strength and stiffness for composite lay-up tooling, surgical guides and high-temperature aerospace and automotive parts, from prototype to production. Its mechanical profile handles demanding load conditions.
XZ samples are printed on edge and ZX samples stand upright, so the ZX values describe strength across the layers, where ULTEM 1010 is much weaker in tension. Stratasys reports no yield point in tension, so strength is given at break, and on-edge (XZ) samples bend past 5% strain without breaking. Orient load-bearing features so stress runs along the layers.
PropertyValue
- Tensile Strength at Break (XZ)ASTM D638
- 79.2 MPa
- Tensile Strength at Break (ZX)ASTM D638
- 28.2 MPa
- Tensile Modulus (XZ)ASTM D638
- 3040 MPa
- Tensile Modulus (ZX)ASTM D638
- 3000 MPa
- Elongation at Break (XZ)ASTM D638
- 4.0 %
- Elongation at Break (ZX)ASTM D638
- 1.1 %
- Flexural Strength at 5% Strain (XZ)ASTM D790, Procedure A
- 128 MPa
- Flexural Strength at Break (XZ)ASTM D790, Procedure A
- No break
- Flexural Strength at Break (ZX)ASTM D790, Procedure A
- 81.6 MPa
- Flexural Modulus (XZ)ASTM D790, Procedure A
- 2910 MPa
- Flexural Modulus (ZX)ASTM D790, Procedure A
- 2640 MPa
- Flexural Strain at Break (XZ)ASTM D790, Procedure A
- No break
- Flexural Strain at Break (ZX)ASTM D790, Procedure A
- 3.2 %
- Compressive Modulus (XZ)ASTM D695
- 2930 MPa
- Compressive Modulus (ZX)ASTM D695
- 3230 MPa
- Izod Impact, Notched (XZ)ASTM D256
- 26.6 J/m
- Izod Impact, Notched (ZX)ASTM D256
- 21.7 J/m
- Izod Impact, Unnotched (XZ)ASTM D4812
- 260 J/m
- Izod Impact, Unnotched (ZX)ASTM D4812
- 68 J/m
Material makeup
Physical properties
Consistent density and surface quality keep critical features in tolerance and downstream finishing predictable. Parts are lighter than the metal tools and housings they replace, and the material's dimensional stability minimizes warpage.
Stratasys measures specific gravity on a moulded plaque, the reference value for the resin itself.
PropertyValue
- Specific Gravity (moulded plaque)ASTM D792
- 1.29
Heat performance
Thermal properties
ULTEM 1010 maintains dimensional stability through temperature swings and repeated thermal cycling, which suits aerospace tooling, sterilized medical parts and under-hood automotive components. Heat deflection is reported flat (XY) and on edge (XZ) at both loads, and sits close to the glass transition temperature, so parts keep their shape under load until the resin begins to soften.
ULTEM 1010 is amorphous, so it has no melting point. Glass transition, thermal conductivity and diffusivity are measured on moulded plaques, and thermal expansion is reported over the temperature range listed with each value.
PropertyValue
- HDT @ 0.45 MPa / 66 psi (XY / XZ)ASTM D648 Method B
- 216.9 / 217.1 °C
- HDT @ 1.82 MPa / 264 psi (XY / XZ)ASTM D648 Method B
- 215.1 / 214.5 °C
- Glass Transition Temperature (moulded plaque)ASTM D7426
- 209 °C
- Mean CTE (XY, −50 to 60 °C)ASTM E831
- 36.1 ×10⁻⁶/K
- Mean CTE (XY, 60 to 205 °C)ASTM E831
- 29.8 ×10⁻⁶/K
- Mean CTE (XZ, −50 to 110 °C)ASTM E831
- 32.5 ×10⁻⁶/K
- Mean CTE (XZ, 110 to 165 °C)ASTM E831
- 16.2 ×10⁻⁶/K
- Mean CTE (XZ, 165 to 200 °C)ASTM E831
- 4.3 ×10⁻⁶/K
- Thermal Conductivity (0 to 90 °C, moulded plaque)ASTM E1952
- 0.242–0.243 W/m·K
- Thermal Diffusivity (0 to 90 °C, moulded plaque)ASTM E1952
- 0.121–0.158 mm²/s
Functional performance
Electrical properties
ULTEM 1010 offers high resistivity and a stable dielectric constant for electrical housings, connectors, insulating features and functional prototypes, and gives enclosures in integrated electrical systems dependable insulation.
Stratasys reports dielectric constant at 1 kHz and 2 MHz for flat and on-edge samples and volume resistivity on a moulded plaque. Dielectric losses were below the resolution of its measurement, so no dissipation factor is listed. Dielectric strength comes from Stratasys's earlier ULTEM 1010 specification sheet.
PropertyValue
- Volume Resistivity (moulded plaque)ASTM D257
- > 7.0×10¹⁴ Ω·cm
- Dielectric Constant, 1 kHz (XY / XZ)ASTM D150
- 2.84 / 2.89
- Dielectric Constant, 2 MHz (XY / XZ)ASTM D150
- 3.09 / 3.16
- Dielectric StrengthASTM D149, Method A
- 240 V/mil
Compatibility data
Chemical properties
Stratasys rates ULTEM 1010 by chemical class at room temperature. It stands up best to fuels, engine coolant, washer fluid and aromatic hydrocarbons, and handles short-term contact with oils, greases, brake and transmission fluid and alcohols. Ketones, strong acids and halogenated hydrocarbons, shown as poor, carry Stratasys's limited rating (likely to degrade the part in short-term exposure), and phenols attack it.
Chemical ratings are screening guidance; confirm them with application-specific testing before production release.
ChemicalRating
- Petroleum fuels
- Excellent
- Aromatic hydrocarbons (e.g. benzene)
- Excellent
- Antifreeze / engine coolant
- Excellent
- Windshield washer fluid
- Excellent
- Weak bases (pH 8–10)
- Excellent
- Deionized water
- Excellent
- Aliphatic hydrocarbons (e.g. propane, butane)
- Good
- Motor oil
- Good
- Transmission fluid
- Good
- Brake fluid
- Good
- Petroleum greases
- Good
- Silicone greases and oils
- Good
- Alcohol / ethanol
- Good
- Esters
- Good
- Weak acids (pH 3–6)
- Good
- Strong bases (pH > 10)
- Good
- Strong acids (pH < 3)
- Limited
- Ketones (e.g. MEK, acetone)
- Limited
- Halogenated hydrocarbons (e.g. CFCs)
- Limited
- Phenols
- Poor
Compliance
Compliance profile
ULTEM 1010 is rated UL 94 V-0 on Stratasys's UL listing and has inherent flame retardant properties. In ASTM E595 testing it showed low outgassing, inside the common screening limits for vacuum and space hardware.
The Stratasys certified grade (CG) is approved for food contact under NSF 51 and meets ISO 10993 and USP Class VI, so teams can start regulatory reviews from supplier data. ULTEM 1010 carries no current FAR 25.853 data, so aircraft cabin parts use ULTEM 9085 or Antero 800NA.
StandardStatus
- UL 94 flammabilityUL Blue Card (file E345258): V-0 at 1.0 mm on F900 and Fortus 900mc for T14 parts built vertically; the T14 horizontal and T20 listings (1.5 to 3.0 mm) cover Fortus 400mc and 450mc builds
- V-0
- ASTM E595 (Outgassing)TML 0.55–0.58%, CVCM 0.02–0.03% on printed samples; full report available from Stratasys
- Stratasys tested
- NSF 51 (Food equipment materials)Certified grade (CG) filament is approved for food contact
- Stratasys CG grade
- ISO 10993 / USP Class VI (Biocompatibility)Certified grade (CG) filament is biocompatible
- Stratasys CG grade
Resources
Datasheets and design resources
Datasheets, design guidance and supplier documentation for ULTEM 1010.
Download center
Access the most recent datasheet and supporting documentation maintained by our engineering team.
ULTEM 1010 datasheetDesign guidelines
Explore printable geometry recommendations, wall thickness tips, and finishing playbooks for FDM.
View FDM design guide
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. It runs on industrial FDM platforms with heated chambers and qualified material profiles for consistent layer adhesion and mechanical integrity.
- Tolerance
- ±0.25 mm or ±0.3%, whichever is greater
- Production capacity
- Multiple parts or assemblies in each large-format build
- Quality control
- In-process monitoring and batch traceability for consistent part quality and material properties
- Colours & finishes
- Natural amber; support removal, machining, sanding, drilling, tapping and vapor polishing
Frequently Asked Questions
Frequently asked questions about ULTEM 1010
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- ULTEM 1010 has the highest heat resistance of any FDM thermoplastic, with a glass transition temperature of 209 °C and heat deflection of about 217 °C at 0.45 MPa and 215 °C at 1.82 MPa. It reaches 79.2 MPa tensile strength along the layers, is rated UL 94 V-0 and resists a wide range of fuels and industrial chemicals, making it suitable for aerospace and medical device applications.
- ULTEM 1010 is printed by FDM on Stratasys Fortus systems with heated build chambers, in 0.254 to 0.330 mm layers and parts up to 914 × 610 × 914 mm, with breakaway support. It is used for high-performance prototypes, composite and manufacturing tooling, and production parts exposed to high temperatures.
- ULTEM 1010 is used for composite lay-up tools, caul plates, vacuum-bagging mandrels, bonding jigs and trim and drill fixtures, out-of-cabin aerospace parts and ducting, under-hood automotive housings, ducts and heat shields, surgical guides and sterilizable instrument trays, and temperature-resistant dies, patterns, fixtures, conveyor and packaging equipment parts for food production. It also makes high-temperature manufacturing fixtures, environmental-chamber test fixtures, semiconductor fixtures and electrical insulation components.
- ULTEM 1010 keeps its shape under load above 200 °C, withstands steam autoclaving and composite cure cycles up to 177 °C, and is available in a certified grade with NSF 51 food-contact approval and ISO 10993 and USP Class VI biocompatibility. It is rated UL 94 V-0, shows low outgassing in ASTM E595 testing, insulates electrically, and Stratasys rates it excellent against fuels and engine coolant.
- ULTEM 1010 costs more than standard FDM thermoplastics such as ABS, ASA and polycarbonate, and prints only in natural amber. It is much weaker across the layers, at 28.2 MPa upright against 79.2 MPa on edge, so parts need careful orientation. Ketones, strong acids, halogenated hydrocarbons and phenols attack it, support is breakaway only, and the filament is moisture sensitive and must be dried and stored properly.
- Yes. ULTEM 1010 withstands steam autoclaving, and Stratasys lists surgical guides and instrument sterilization trays among its uses. The certified grade meets ISO 10993 and USP Class VI. Stratasys's data sheet gives no ethylene oxide or gamma data and no cycle count, so the device maker validates the sterilization method for each part.
- ULTEM 1010 is used for out-of-cabin and high-heat aerospace parts and tooling. It is rated UL 94 V-0, but current Stratasys data carries no FAR 25.853 flame, smoke and toxicity results, so cabin interior parts are printed in ULTEM 9085 or Antero 800NA.
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