FDM TechnologyThermoplastic

Aerospace-Grade ExcellenceHigh-Performance Thermoplastic for Mission-Critical Applications

ULTEM 9085 is a highly versatile and reliable thermoplastic that has earned its reputation as a go-to material for demanding applications. Its exceptional strength-to-weight ratio, heat resistance, flame, smoke, and toxicity rating, and documented traceability make it an ideal choice for industries seeking reliable and high-performance solutions.

Tensile Strength
69.2 MPa
Flexural Modulus
2.40 GPa
Temperature Resistance
176.9 °C
Technology
FDM
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ULTEM 9085 3D printed part example
Large Build Volume
Cost-Effective
FDM material

ULTEM 9085 overview

ULTEM 9085 is considered an engineering grade Fused Deposition Modeling (FDM) thermoplastic renowned for its exceptional strength-to-weight ratio and flame-retardant properties. This polyetherimide (PEI) blend offers superior mechanical performance and ease of printing, making it ideal for demanding engineering applications. With its exceptional glass transition temperature of 177°C and compliance with multiple aerospace and railway FST standards, ULTEM 9085 enables innovative designs and durable components that excel in the most challenging environments. The material's documented traceability and certified grade options provide the quality assurance required for critical applications.

Why manufacture with ULTEM 9085

ULTEM 9085 combines exceptional strength-to-weight ratio for lightweight high-performance parts and outstanding flame, smoke, and toxicity (fst) performance meeting aerospace standards, delivering high glass transition temperature (177°c) for superior thermal stability for demanding applications. From rapid prototyping to production runs, teams rely on ULTEM 9085 to maintain tight tolerances while reducing assembly complexity through consolidated part designs.

FDM Production Technology

ULTEM 9085 sets the FDM benchmark for aerospace certification with FST (flame, smoke, toxicity) compliance and 153°C heat deflection temperature. The Stratasys Fortus 450mc's high-temperature system maintains 360°C extrusion and 195°C chamber temperatures, ensuring complete PEI crystallization for optimal strength. With 69 MPa tensile strength and exceptional chemical resistance, ULTEM 9085 produces flight-ready components, from air ducts to structural brackets. The material's certifications for aircraft interiors (FAR 25.853) and food contact (NSF 51) enable applications spanning aerospace cabins to medical device manufacturing where regulatory compliance is mandatory.

Build Volume

914 × 610 × 914 mm (36 × 24 × 36 in)

Max part size

Lead Time

2-4 business days

Fast turnaround available

Layer Height

0.254 mm (0.010 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 9085.

ULTEM 9085 FDM cube sample showing high-performance thermoplastic properties
Technical resources

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Technical datasheet

Detailed specs for ULTEM 9085.

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Applications & field work

Where ULTEM 9085 excels

ULTEM 9085 combines exceptional strength-to-weight ratio with certified flame, smoke, and toxicity (FST) performance, making it the aerospace industry's preferred FDM thermoplastic. With documented lot traceability and compliance with 14 CFR 25.853 standards, every build delivers the accountability required for flight-certified components.

The material's 177°C glass transition temperature and outstanding chemical resistance enable parts to survive autoclave cycles, paint baking, and exposure to aviation fluids without degradation. This durability, combined with inherent flame retardancy (UL94 V-0), allows ULTEM 9085 to replace traditionally machined components in both cabin and out-of-cabin applications.

Forge Labs' Fortus 900mc systems with precise thermal control ensure consistent mechanical properties across large builds up to 914mm, critical for aerospace tooling and production parts. Our documented quality system provides full material traceability from powder lot through finished part, meeting AS9100 requirements.

Mechanical
Tensile Strength (XZ Axis): 69.2 MPa
ASTM D638 - 69 MPa tensile strength
Thermal
Heat Deflection Temperature @ 66 psi: 176.9 °C
HDT 177°C @ 0.45 MPa
Physical
Density: 1.27 g/cm³
Electrical
Volume Resistivity: 6.89×10¹⁵ Ω·cm
UL94 V-0 flame rating
FDM applications showcase
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Industry applications for ULTEM 9085

From commercial aviation to defense platforms, ULTEM 9085 enables lightweighting strategies and rapid iteration of high-performance components. Explore how aerospace leaders leverage this certified material.

ULTEM 9085 meets stringent aerospace FST requirements while enabling complex geometries impossible with traditional manufacturing. The material's certified grades provide the traceability and consistency required for flight-critical applications.

Key Applications

  • Aircraft interior panels and ducting systems
  • Electrical component housings and wire management
  • Custom brackets for avionics and instrumentation
  • Environmental control system components

Performance Data

Meets 14 CFR 25.853 with 12-second vertical burn, <200 smoke density, and low toxicity emissions, certified for unlimited cabin use.

Explore commercial & defense aviation

The automotive industry leverages ULTEM 9085 for under-hood components and electrical systems that demand thermal stability and chemical resistance. The material withstands continuous exposure to 170°C while maintaining structural integrity.

Key Applications

  • Turbocharger housings and heat shields
  • High-voltage battery enclosures
  • Sensor brackets for engine compartments
  • Custom air intake components

Performance Data

Maintains 90% tensile strength after 1000 hours at 150°C, with resistance to automotive fluids including coolant, oil, and brake fluid.

Explore high-performance automotive

ULTEM 9085 meets EN 45545-2 and NFPA 130 standards for rail applications, enabling lightweight interior components that enhance passenger safety. The material's low smoke and toxicity characteristics are critical for tunnel operations.

Key Applications

  • Interior paneling and ventilation grilles
  • Electrical junction boxes and cable management
  • Custom seat components and armrests
  • Emergency equipment housings

Performance Data

Achieves HL2 classification per EN 45545-2 with R1/R6/R7 requirements, enabling use in underground and mainline rail applications.

ULTEM 9085's excellent dielectric properties combined with flame retardancy make it ideal for high-temperature electronic applications. The material maintains electrical insulation properties even at elevated temperatures.

Key Applications

  • High-temperature PCB carriers and fixtures
  • RF transparent radomes and antenna housings
  • Power distribution enclosures
  • Test fixtures for burn-in chambers

Performance Data

Volume resistivity of 6.89×10¹⁵ Ω·cm with dielectric strength of 830 V/mil, maintaining insulation properties up to 170°C continuous use.

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ULTEM 9085 production examples

FDM applications showcase

FDM applications showcase

Industrial FDM Applications

Aerospace ULTEM 9085 component

Aerospace ULTEM 9085 component

Aerospace Application

High-temperature aerospace ducting made with ULTEM 9085

High-temperature aerospace ducting made with ULTEM 9085

Aerospace Ducting

Performance Dashboard

Technical performance for ULTEM 9085

ULTEM 9085 delivers dependable strength and impact resistance for Aircraft cabin interior components and ducting and Automotive under-hood brackets and housings, helping teams move from prototype to production with confidence.

Mechanical Properties

Tensile Strength (XZ Axis)

69.2 MPa

ULTEM 9085 records Tensile Strength (XZ Axis) at 69.2 MPa, reinforcing its mechanical properties story.

Mechanical Properties

Tensile Strength (ZX Axis)

39.4 MPa

ULTEM 9085 records Tensile Strength (ZX Axis) at 39.4 MPa, reinforcing its mechanical properties story.

Mechanical Properties

Flexural Strength (XZ Axis)

104 MPa

ULTEM 9085 records Flexural Strength (XZ Axis) at 104 MPa, reinforcing its mechanical properties story.

ULTEM 9085 combines Exceptional strength-to-weight ratio for lightweight high-performance parts and Outstanding flame, smoke, and toxicity (FST) performance meeting aerospace standards to support Aircraft cabin interior components and ducting and Automotive under-hood brackets and housings that demand production-ready durability.

Measurement
ULTEM 9085Base
Standard
Tensile Strength (XZ Axis)69.2 MPa—
Tensile Strength (ZX Axis)39.4 MPa—
Flexural Strength (XZ Axis)104 MPa—
Flexural Strength (ZX Axis)73.1 MPa—
Compressive Strength (XZ Axis)139 MPa—
Compressive Strength (ZX Axis)342 MPa—
Tensile Modulus (XZ Axis)2.52 GPa—
Tensile Modulus (ZX Axis)2.41 GPa—
Flexural Modulus (XZ Axis)2.40 GPa—
Flexural Modulus (ZX Axis)2.13 GPa—
Impact Strength (XZ Axis)88.5 J/m—
Impact Strength (ZX Axis)39.2 J/m—
Elongation at Break (XZ Axis)5.4 %—
Elongation at Break (ZX Axis)1.9 %—
Mechanical Performance

Mechanical Properties

ULTEM 9085 delivers dependable strength and impact resistance for Aircraft cabin interior components and ducting and Automotive under-hood brackets and housings, helping teams move from prototype to production with confidence.

ULTEM 9085 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 Aircraft cabin interior components and ducting, Automotive under-hood brackets and housings, and Railway interior fire-resistant components, providing long-term durability in demanding environments. ULTEM 9085 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, Automotive, and Railway. 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 9085 combines Exceptional strength-to-weight ratio for lightweight high-performance parts and Outstanding flame, smoke, and toxicity (FST) performance meeting aerospace standards to support Aircraft cabin interior components and ducting and Automotive under-hood brackets and housings that demand production-ready durability.

Key metric

Tensile Strength (XZ Axis)

69.2 MPa

Key metric

Tensile Strength (ZX Axis)

39.4 MPa

Key metric

Flexural Strength (XZ Axis)

104 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 9085 offers consistent density and surface quality so critical features hold tolerances and downstream finishing remains predictable.

ULTEM 9085 exhibits a density of 1.27 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 Aircraft cabin interior components and ducting, Automotive under-hood brackets and housings, and Railway interior fire-resistant components. The material's inherent characteristics minimize warpage and maintain tight tolerances throughout the part lifecycle.

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

ULTEM 9085 delivers 1.27 g/cm³ density so assemblies fit and finish without secondary rework.

Key metric

Density

1.27 g/cm³

Key metric

Water Absorption (24 hours)

0.25 %

Key metric

Water Absorption (Saturation)

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 9085 maintains dimensional stability through temperature swings, making it a reliable option for Aerospace and Automotive programs that see repeated thermal cycling.

ULTEM 9085 demonstrates excellent thermal stability with a heat deflection temperature of 176.9 °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 Aircraft cabin interior components and ducting, Automotive under-hood brackets and housings, and Railway interior fire-resistant components that experience temperature fluctuations. Its ability to withstand thermal cycling without degradation ensures long-term reliability in Aerospace, Automotive, and Railway.

With broad temperature tolerance, ULTEM 9085 provides engineers with confidence when designing parts for thermally demanding applications, from under-hood automotive components to industrial equipment exposed to heat sources.

ULTEM 9085 maintains geometry with a Heat Deflection Temperature @ 66 psi of 176.9 °C, protecting dimensional integrity during heat cycling.

Key metric

Heat Deflection Temperature @ 66 psi

176.9 °C

Key metric

Heat Deflection Temperature @ 264 psi

172.9 °C

Key metric

Glass Transition Temperature

177.3 °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 9085 provides predictable electrical behavior for housings and functional prototypes that need controlled resistivity and dielectric strength.

ULTEM 9085 provides controlled electrical resistivity of 6.89×10¹⁵ Ω·cm, making it suitable for electrical housings and insulators. Its dielectric strength of 830 V/mil ensure reliable performance in electrical assemblies.

These electrical characteristics enable its use in Aircraft cabin interior components and ducting, Automotive under-hood brackets and housings, and Railway interior fire-resistant components where electrical performance is critical. The material maintains consistent electrical properties across its operating temperature range, ensuring stable performance in varying conditions.

For Aerospace, Automotive, and Railway requiring precise electrical behavior, ULTEM 9085 delivers the consistency and reliability needed for functional prototypes and production parts that interact with electrical systems.

ULTEM 9085 posts 6.89×10¹⁵ Ω·cm Volume Resistivity, giving enclosures dependable insulating performance.

Key metric

Volume Resistivity

6.89×10¹⁵ Ω·cm

Key metric

Dielectric Constant (1 kHz)

2.80

Key metric

Dielectric Constant (2 MHz)

2.65

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 9085 offers tested chemical resistance across acids, bases, solvents, and hydrocarbons to ensure reliable performance in harsh environments.

ULTEM 9085 demonstrates broad chemical resistance with testing against 12 different chemicals, showing excellent compatibility with 4 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 Aircraft cabin interior components and ducting, Automotive under-hood brackets and housings, and Railway interior fire-resistant components that require exposure to aggressive chemicals. Its chemical inertness ensures parts maintain their mechanical properties even after prolonged chemical exposure.

For Aerospace, Automotive, and Railway, this chemical stability translates to longer service life and reduced maintenance requirements, making ULTEM 9085 a cost-effective choice for chemically demanding applications.

ULTEM 9085 has been tested against 12 chemicals with 4 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 9085

Evaluate how ULTEM 9085 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
Aliphatic HydrocarbonsHydrocarbonGood
Mineral OilsHydrocarbonGood
Weak AcidsAcidGood
Weak BasesBaseGood
Strong AcidsAcidPoor
Strong BasesBasePoor
KetonesSolventPoor
Aromatic HydrocarbonsHydrocarbonPoor
Medical Readiness

Biocompatibility and compliance profile

ULTEM 9085 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
14 CFR 25.853CertifiedFederal Aviation Regulation for cabin materials FST
AITM 2.0007B & 3.0005CertifiedAirbus industry test methods for FST
BSS 7238 & 7239CertifiedBoeing Specification Support Standards for FST
ASTM E595CertifiedNASA outgassing standard for space applications
EN 45545-2CertifiedEuropean fire protection standard for railway vehicles
NFPA 130CertifiedFire protection for fixed guideway transit systems
UN ECE Regulation 118CertifiedFire protection of buses and coaches
RoHSCertifiedRestriction of Hazardous Substances Directive
USP Class VICertifiedBiocompatibility for medical devices

Medical-ready programs

Common applications our medical customers pursue with ULTEM 9085.

  • Medical device enclosures and sterilizable parts
Resources

Datasheets and design resources

Equip your team with certification packs, design guides, and spec sheets tailored to ULTEM 9085.

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
14 CFR 25.853Certified
AITM 2.0007B & 3.0005Certified

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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.

FDM Manufacturing Lab

ULTEM 9085 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
0.254 mm (0.010 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

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Frequently Asked Questions

Frequently asked questions about ULTEM 9085

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ULTEM 9085 is known for its exceptional strength-to-weight ratio for lightweight high-performance parts, outstanding flame, smoke, and toxicity (fst) performance meeting aerospace standards, high glass transition temperature (177°c) for superior thermal stability, making it suitable for aerospace and automotive applications.

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