Aerospace
Aircraft Systems & Avionics Enclosures
Black controller enclosures with cable guides, inspected and shipped in about two and a half weeks.
Fused Deposition Modeling ULTEM 9085 For Flame-Resistant Aerospace Interior Parts
Large Build Volume
Up to 914 × 610 × 914 mm
FDM material
ULTEM 9085 overview
ULTEM 9085 is a strong, lightweight, flame-retardant plastic for finished aircraft, rail and enclosure parts, made by Fused Deposition Modeling (FDM) 3D printing with no tooling. It has been tested to aircraft and railway standards for flame, smoke and toxic fumes, so printed ducts, panels and brackets can replace machined parts in cabins and trains. It stays stable in hot service, holds up to fuels, alcohols and water-based fluids, and is tough enough to survive handling during installation. Choose it for cabin interiors, avionics and power enclosures, rail and bus interior parts, and lightweight replacements for machined brackets and fittings.
How ULTEM 9085 is manufactured
ULTEM 9085 is manufactured using Fused Deposition Modeling (FDM) on Stratasys Fortus production systems, which build parts layer by layer from PEI filament in a heated chamber, with no tooling. Forge Labs' Fortus 900mc systems with precise thermal control ensure consistent mechanical properties across large builds, critical for aerospace tooling and production parts. Breakaway supports carry overhangs and internal features during the build, so parts from air ducts to structural brackets print in their final shape.
- Build volume
- 914 × 610 × 914 mm
- Lead time
- 2-4 business days
- Layer height
- 0.254-0.330 mm
Forge Labs Steam
Know before you manufacture in ULTEM 9085.
Upload CAD files to Forge Labs Steam for instant ULTEM 9085 pricing and live manufacturability feedback, and fix issues before production.
Upload CAD files to Forge Labs Steam for instant ULTEM 9085 pricing and live manufacturability feedback, and fix issues before production.
Industry applications
Industry applications for ULTEM 9085
ULTEM 9085 combines light weight and high strength with flame, smoke and toxicity (FST) performance tested to aerospace standards, making it a go-to FDM thermoplastic for aircraft interiors.
Its high glass transition temperature and broad resistance to petroleum fuels, hydrocarbons, alcohols and aqueous solutions keep parts stable in hot, fluid-exposed service. This durability, combined with inherent flame retardancy (UL 94 V-0), allows ULTEM 9085 to replace traditionally machined components in both cabin and out-of-cabin applications.
From rapid prototyping to production runs, teams rely on ULTEM 9085 to maintain tight tolerances while reducing assembly complexity through consolidated part designs. It balances strength and flexibility, unlike the more rigid ULTEM 1010, so housings, brackets and clips survive handling during installation and servicing.
Beyond aircraft and rail interiors, underwater vehicle builders choose it for interior parts that must be flame retardant, defense teams for ruggedized housings, and production lines for high-temperature jigs, fixtures and semiconductor tooling. Its low dielectric constant and electrical insulation suit RF-transparent radomes, antenna housings and PCB carriers, and its low thermal conductivity suits thermal insulation parts.
Aircraft Interiors
Cabin Ducting, Panels & Brackets
Ducts, panels and brackets that meet 14 CFR 25.853, with large ducts printed in one piece.
Power Generation
Engine Intake Fittings Replacing Aluminium
An intake fitting drawn in 6061-T6 aluminium, made in black ULTEM 9085 at solid infill.
Clean Tech
Fuel Cell Brackets & Power Enclosures
Flame-rated fuel cell brackets in a UL 94 V-0 listed material.
Rail & Transit
Rail & Bus Interior Parts
Interior parts for underground and mainline rail, reaching EN 45545-2 HL3 at 10 mm.
Aerospace
Aircraft Systems & Avionics Enclosures
Aircraft systems makers use ULTEM 9085 for controller enclosures, wire management and instrument brackets, where heat resistance, low weight and electrical insulation matter together. On black enclosures for aircraft water-system controllers, the drawing fixed the material, the FDM process and the build direction, internal cable guides were refined through print trials, and first article inspection checked the mounting features. Samples shipped in about two and a half working weeks, with orientation and print settings recorded for repeat orders.
- Avionics and controller enclosures
- Wire management and cable guides
- Instrument and equipment brackets
Aircraft Interiors
Cabin Ducting, Panels & Brackets
Cabin and environmental control teams use ULTEM 9085 for air ducts, interior panels and brackets that must meet aircraft fire rules. It meets 14 CFR 25.853, including 60-second and 12-second vertical burns and heat release, and its smoke density of 4 to 15 in Boeing BSS 7238 testing is far below the FAA limit of 200, with low toxic gas emissions. Large ducts print in one piece, so assemblies that once needed several moulded or bonded sections become a single part.
- Interior panels and ducting systems
- Environmental control system components
- Cabin brackets and trim
Power Generation
Engine Intake Fittings Replacing Aluminium
Power generation developers use ULTEM 9085 where a low-load metal part can become a lighter polymer one. On a set of prototype engine parts, an intake fitting drawn in 6061-T6 aluminium was made in black ULTEM 9085 by FDM at solid infill. Swaps like this are checked for strength across the layers and heat near the engine, where ULTEM 9085 has a heat deflection temperature of 170 °C at 1.82 MPa.
- Intake fittings and manifolds
- Engine-bay brackets and covers
- Machined-part replacements
Clean Tech
Fuel Cell Brackets & Power Enclosures
A fuel cell maker orders flame-rated ULTEM 9085 brackets, and the same material suits power distribution enclosures and fluid-line fittings in energy equipment. It is UL 94 V-0 listed at walls as thin as 0.508 mm for horizontal builds and 1.016 mm for vertical builds at 0.254 mm layers, so brackets and covers designed to those walls are flame retardant with no added coating.
- Flame-rated fuel cell brackets
- Power distribution enclosures
- Fluid and air-line fittings
Rail & Transit
Rail & Bus Interior Parts
Rail and bus builders use ULTEM 9085 for interior panels, ventilation grilles and junction boxes, where low smoke and toxicity matter most in tunnels. It reaches EN 45545-2 HL2 at 1 mm and HL3 at 10 mm for requirements R1, R6 and R7, and the certified grade has a flame spread index of 0 in the ASTM E162 test NFPA 130 calls for and does not ignite in UN ECE Regulation 118 bus tests.
- Interior paneling and ventilation grilles
- Junction boxes and emergency equipment housings
- Seat components and armrests
Performance data
Technical performance for ULTEM 9085
Values from the Stratasys ULTEM 9085 datasheets, tested to the standard listed with each property.
Mechanical performance
Mechanical properties
ULTEM 9085 delivers dependable strength and impact resistance for aircraft cabin components and ducting, brackets and housings. Its balanced mechanical profile handles demanding load conditions, with strength, elongation and impact resistance far higher along the layers than across them.
XZ values come from specimens printed on edge and ZX values from upright specimens loaded across the layers, so orient loaded features, mounting tabs and clips along the build plane and size parts against the ZX figures.
PropertyValue
- Tensile Strength at Yield (XZ)ASTM D638
- 69.2 MPa
- Tensile Strength at Break (XZ)ASTM D638
- 68.1 MPa
- Tensile Strength at Break (ZX)ASTM D638
- 39.4 MPa
- Tensile Modulus (XZ)ASTM D638
- 2520 MPa
- Tensile Modulus (ZX)ASTM D638
- 2410 MPa
- Elongation at Yield (XZ)ASTM D638
- 5.4 %
- Elongation at Break (XZ)ASTM D638
- 5.4 %
- Elongation at Break (ZX)ASTM D638
- 1.9 %
- Flexural Strength (XZ)ASTM D790, Procedure A
- 104 MPa
- Flexural Strength (ZX)ASTM D790, Procedure A
- 73.1 MPa
- Flexural Modulus (XZ)ASTM D790, Procedure A
- 2400 MPa
- Flexural Modulus (ZX)ASTM D790, Procedure A
- 2130 MPa
- Flexural Strain at Break (XZ)ASTM D790, Procedure A
- No break (test stopped at 5%)
- Flexural Strain at Break (ZX)ASTM D790, Procedure A
- 3.7 %
- Compressive Peak Strength (XZ)ASTM D695
- 139 MPa
- Compressive Modulus (XZ)ASTM D695
- 2220 MPa
- Compressive Modulus (ZX)ASTM D695
- 2280 MPa
- Izod Impact, Notched (XZ)ASTM D256
- 88.5 J/m
- Izod Impact, Notched (ZX)ASTM D256
- 39.2 J/m
- Izod Impact, Unnotched (XZ)ASTM D4812
- 647 J/m
- Izod Impact, Unnotched (ZX)ASTM D4812
- 187 J/m
Material makeup
Physical properties
Low density makes ULTEM 9085 parts lightweight yet durable, and consistent surface quality keeps critical features in tolerance and downstream finishing predictable. The oxygen index shows how much oxygen the material needs to keep burning, well above the level of normal air, which underpins its flame retardancy.
Low outgassing in ASTM E595 vacuum testing suits enclosed and space hardware, and stress at break is practically unchanged after accelerated UV exposure, so parts hold their strength under cabin lighting and sunlight.
PropertyValue
- Specific Gravity (molded)ASTM D792
- 1.27
- Limiting Oxygen Index (0.55 / 10.5 mm, XY)ISO 4589-2
- 37.2 / 47.9 %
- Outgassing, Total Mass LossASTM E595
- 0.33–0.37 %
- Outgassing, Collected Volatile Condensable MaterialASTM E595
- < 0.01–0.02 %
- Outgassing, Water Vapor RecoveredASTM E595
- 0.22–0.38 %
- Change in Stress at Break after 1,000 h UV (CG, ZX)ASTM G154
- −0.1 %
Heat performance
Thermal properties
Heat deflection is measured at two loads and in two print directions, and ULTEM 9085 holds its shape close to its glass transition temperature at both, so parts keep their dimensional accuracy in elevated temperature environments, from aircraft cabins to equipment near heat sources.
The retained-strength values show how much of its room-temperature strength the material keeps as it warms, so size parts for their real service temperature rather than the deflection point. In the cold it gets stronger, reaching 157% of its room-temperature strength at break at −54 °C in Stratasys testing, and the expansion coefficients help size clearances on assemblies that see temperature swings.
PropertyValue
- HDT @ 0.45 MPa / 66 psi (XY / XZ)ASTM D648, Method B
- 178.2 / 178.4 °C
- HDT @ 1.82 MPa / 264 psi (XY / XZ)ASTM D648, Method B
- 170.2 / 172.6 °C
- Glass Transition Temperature (molded)ASTM D7426, inflection point
- 177.3 °C
- Coefficient of Thermal Expansion (XY, −50 to 80 °C)ASTM E831
- 44.89 ×10⁻⁶/K
- Coefficient of Thermal Expansion (XY, 80 to 160 °C)ASTM E831
- 31.35 ×10⁻⁶/K
- Coefficient of Thermal Expansion (XZ, −50 to 60 °C)ASTM E831
- 44.45 ×10⁻⁶/K
- Coefficient of Thermal Expansion (XZ, 60 to 160 °C)ASTM E831
- 32.31 ×10⁻⁶/K
- Thermal Conductivity @ 30 °C (molded)ASTM E1952
- 0.21 W/m·K
- Strength at Break Retained @ 82 °C (ZX)ASTM D638
- 102 %
- Strength at Break Retained @ 104 °C (ZX)ASTM D638
- 87 %
- Strength at Break Retained @ 132 °C (ZX)ASTM D638
- 70 %
- Strength at Break Retained @ 149 °C (ZX)ASTM D638
- 55 %
Functional performance
Electrical properties
High volume resistivity and a low dielectric constant make ULTEM 9085 a dependable insulator for electrical housings, connectors, insulating features and functional prototypes.
Dielectric constant is given at 1 kHz and 2 MHz in two print directions, and dissipation factor at both frequencies. Low values mean low dielectric losses in signal-sensitive or high-frequency parts.
PropertyValue
- Volume Resistivity (molded)ASTM D257
- > 6.89×10¹⁵ Ω·cm
- Dielectric Constant @ 1 kHz (XY / XZ)ASTM D150
- 2.80 / 2.87
- Dielectric Constant @ 2 MHz (XY / XZ)ASTM D150
- 2.65 / 2.73
- Dissipation Factor @ 1 kHzASTM D150
- 0.002
- Dissipation Factor @ 2 MHzASTM D150
- 0.010
- Dielectric StrengthASTM D149, Method A
- 4.3–11.4 kV/mm
Compatibility data
Chemical properties
Stratasys rates ULTEM 9085 on a relative scale for common chemical classes. It resists petroleum fuels, washer fluid, water and weak bases, and holds up well to aliphatic and aromatic hydrocarbons, alcohols, esters, motor oil, greases, coolant, weak acids and strong bases. Resistance is limited to ketones, strong acids, brake fluid and transmission fluid, while halogenated hydrocarbons and phenols attack it.
Stratasys notes the ratings are relative rather than based on specific testing, so treat them as screening guidance and confirm them with application-specific testing before production release.
ChemicalRating
- Petroleum fuels
- Excellent
- Windshield washer fluid
- Excellent
- Weak bases (pH 8–10)
- Excellent
- Deionized water
- Excellent
- Aliphatic hydrocarbons
- Good
- Aromatic hydrocarbons
- Good
- Alcohol / ethanol
- Good
- Esters
- Good
- Motor oil
- Good
- Petroleum greases
- Good
- Silicone greases and oils
- Good
- Antifreeze / engine coolant
- Good
- Weak acids (pH 3–6)
- Good
- Strong bases (pH > 10)
- Good
- Ketones (MEK, acetone)
- Limited
- Strong acids (pH < 3)
- Limited
- Transmission fluid
- Limited
- Brake fluid
- Limited
- Halogenated hydrocarbons (CFCs)
- Poor
- Phenols
- Poor
Compliance
Compliance profile
ULTEM 9085 is inherently flame retardant, with a UL 94 V-0 listing on its UL Blue Card. Stratasys has tested it to the aircraft, rail and bus fire standards listed here, along with ASTM E595 outgassing, and states that the tests show compliance with each tested standard rather than certification, so aircraft and vehicle programs start their part qualification from supplier data.
Stratasys publishes no biocompatibility or food-contact data for ULTEM 9085; ULTEM 1010 carries those for its certified grade.
StandardStatus
- UL 94 flammabilityUL Blue Card E345258: V-0 from 0.508 mm (horizontal build) and 1.016 mm (vertical build) at 0.254 mm layers
- V-0
- 14 CFR 25.853 (FAR 25.853)60 s and 12 s vertical burn, 15 s horizontal burn and heat release requirements met on F900-printed samples
- Stratasys tested
- BSS 7238 & BSS 7239Smoke density and toxic gas emission requirements met (Boeing test methods)
- Stratasys tested
- AITM 2.0007B & AITM 3.0005Smoke density and toxic gas emission requirements met (Airbus test methods)
- Stratasys tested
- ASTM E595 (Outgassing)TML 0.33–0.37% and CVCM ≤ 0.02% across tested natural and black samples
- Stratasys tested
- EN 45545-2 (Rail)R1, R6, R7, R17 HL2 at 1 mm and HL3 at 10 mm; R2, R3 HL3; R22, R23 to HL3 in thin XY sections
- Stratasys tested
- NFPA 130 (Transit)ASTM E162 flame spread index 0 at 12.7 mm; ASTM E662 smoke and ASTM E1354 heat release reported at 3 and 10 mm (certified grade)
- Stratasys tested
- UN ECE Regulation 118 (Buses)Horizontal burning, melting behaviour and vertical burn passed at 3 mm (certified grade, XY)
- Stratasys tested
Related materials
Compare ULTEM 9085 with similar materials
Resources
Datasheets and design resources
Datasheets, design guidance and supplier documentation for ULTEM 9085.
Download center
Access the most recent datasheet and supporting documentation maintained by our engineering team.
ULTEM 9085 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 9085 is manufactured using Fused Deposition Modeling (FDM) technology, offering reliable performance for functional prototypes and end-use parts. Qualified material profiles give strong layer adhesion on every build.
- Tolerance
- ±0.25 mm or ±0.3%, whichever is greater
- Production capacity
- Multiple parts and assemblies in each build
- Quality control
- In-process monitoring and batch traceability for consistent part quality and material properties
- Colours & finishes
- Natural tan or black; support removal, sanding, bead blasting, painting and machining
Frequently Asked Questions
Frequently asked questions about ULTEM 9085
Can't find the answer you're looking for? Reach out to our customer support team.
- ULTEM 9085 combines a high strength-to-weight ratio with inherent flame retardancy (UL 94 V-0 on its UL Blue Card) and flame, smoke and toxicity performance that Stratasys has tested to aerospace and rail standards. Its glass transition temperature is 177 °C, its heat deflection temperature is 170 °C at 1.82 MPa, and its tensile yield strength is 69 MPa along the layers, which suits aerospace, rail and automotive applications.
- ULTEM 9085 is printed by Fused Deposition Modeling (FDM) on Stratasys Fortus systems, with layers from 0.254 to 0.330 mm, parts up to 914 × 610 × 914 mm and breakaway supports. It is used for aircraft cabin components and ducting, avionics enclosures, rail interior parts and engine-bay brackets.
- ULTEM 9085 is used across aerospace, rail and transit, automotive, military and defense, electronics and manufacturing for aircraft interior panels and ducting, controller enclosures and wire management, rail and bus interior parts, high-temperature jigs and fixtures, and electrical insulation components.
- Stratasys has tested ULTEM 9085 to 14 CFR 25.853 (FAR 25.853), including vertical burn and heat release, and to the Boeing BSS 7238 and 7239 and Airbus AITM smoke and toxicity methods. Stratasys states the tests show compliance with the tested standard, not certification, so the aircraft program qualifies the finished part with that supplier data as its starting point.
- ULTEM 9085 gives a high strength-to-weight ratio, inherent flame retardancy and electrical insulation, with volume resistivity above 6.89 × 10¹⁵ Ω·cm. It shows low outgassing in ASTM E595 testing (TML 0.33 to 0.37%, CVCM 0.02% or less) for space applications, resists petroleum fuels, hydrocarbons and alcohols, and is practically unchanged after 1,000 hours of UV exposure.
- ULTEM 9085 is anisotropic: upright parts break at 39.4 MPa against 68.1 MPa along the layers, so orientation matters. It needs a heated chamber and breakaway support, costs more than standard engineering thermoplastics, needs dry storage, and is offered in natural amber and black. Halogenated hydrocarbons and phenols attack it, and Stratasys publishes no biocompatibility data for it.
- Yes, for brackets, sensor mounts, air intake components and battery enclosures near heat. ULTEM 9085 keeps 87% of its room-temperature strength at 104 °C and 70% at 132 °C, and Stratasys rates it excellent against petroleum fuels and good against motor oil and coolant. Its resistance to brake and transmission fluid is limited, and 170 °C is a short-term deflection point, not a continuous service temperature.
Start a quote
Ready to Get Started with ULTEM 9085?
Upload your design and get an instant quote for ULTEM 9085 parts.
- Instant pricing with automated manufacturability analysis
- Production workflows built for repeatable quality
- Engineering support from prototype to production
Create an account to upload CAD
STEP, STL, OBJ, 3MF and IGES supported
- Manufacturing technologies
- 6
- Engineering materials
- 50+
- Part quantities
- 1-500+