| HS Code | 193870 |
| Material Composition | Aluminum-filled nylon |
| Color | Metallic gray |
| Recyclability | Yes |
As an accredited 3D Systems DuraForm AF Nylon for SLS Systems factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
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For low-pressure polyurethane casting tooling, 3D Systems DuraForm AF nylon is processed into core and cavity inserts on CO₂ laser SLS platforms with layer heights between 0.08 mm and 0.12 mm. The aluminum particulate filler raises the thermal conductivity of the printed wall relative to unfilled polyamide 12; published comparative data for this specific grade is limited, but metal-filled PA12 compositions commonly shift from 0.23 W/m·K to 0.45–0.60 W/m·K. Tool surfaces are sealed with a two-component epoxy or cyanoacrylate sealer because as-built SLS surfaces retain interconnected porosity. Without sealing, low-viscosity polyurethane components migrate into void networks and create mechanical adhesion between insert and cast part. Molds are typically run at cavity pressures of 0.3–0.7 MPa with tool temperatures held between 60 °C and 80 °C. Tear-resistant shore A 60–70 polyurethane systems are mixed at supplier-specified ratios, commonly 100:80 parts by weight polyol to isocyanate, then degassed under vacuum at −0.09 MPa before injection. The stiffer aluminum-filled matrix reduces wall deflection in deep ribs with draft angles as low as 0.5°; however, draft below this value increases release force and causes surface delamination at the seal film. Cycle counts for unfilled nylon tooling are frequently limited by core wear after 100–200 cycles; aluminum-filled inserts extend this window by resisting abrasion from filled polyurethane formulations, but published cycle life for DuraForm AF in production casting is application-specific and must be validated through a molded-part trial. Insert failure modes include edge chipping at shut-off surfaces and localized softening if mold temperature exceeds 90 °C during continuous operation. Silicone release agents are avoided when cast parts are subsequently painted because transfer from the insert contaminates the polyurethane surface.
When aluminum-filled nylon is inserted into a steel or aluminum bolster for short-run thermoplastic injection, the limiting variable is not tensile strength but flexural resistance of the unsupported core span. In a typical insert geometry, a core with diameter 6.0 mm and unsupported length 18.0 mm can be molded in polypropylene at cavity pressures up to 25 MPa; at 35 MPa the same core exhibits permanent set after fewer than 50 cycles. This behavior follows from the nonlinear viscoelastic response of the polyamide 12 matrix under sustained clamp force. Molders should design shut-off bearing area to keep specific pressure below 20 MPa on printed surfaces and transfer the main clamp load to a metal frame. Conformal cooling channels with diameter 4.0–6.0 mm are printed directly into the insert, which reduces the steady-state mold surface temperature by 8–12 °C compared with straight-drilled channels in an equivalent steel insert. Cooling water is maintained at 15–20 °C; glycol concentrations above 20 vol% lower heat transfer and are unnecessary below 0 °C ambient. The material is limited to unfilled or lightly filled resins such as PP, HDPE, TPE, and unfilled ABS. Glass-filled resins erode gate regions and should be avoided. Cooling channel layout is generated as a conformal network with a wall distance of 4.0 mm from the cavity surface; flow rates are set to achieve a Reynolds number above 4,000 in 4.0 mm channels. Gate design uses edge or sub-gates with land length 0.8–1.2 mm; smaller gates increase shear heating and degrade PP. After 200 cycles, edge radii at the gate increase by visual inspection, and the insert should be replaced or re-machined if critical dimensions exceed the tolerance band defined in ISO 2768-2. Published data for DuraForm AF in high-pressure injection molding is limited; short-run tooling programs should begin with a mold trial at the lower end of the cavity-pressure range and measure part mass and flash thickness after each 20 shots.
Directly printed gripper fingers in aluminum-filled nylon reduce the mass of a moving end-of-arm assembly when compared with machined aluminum at equivalent envelope dimensions. The density of aluminum-filled polyamide 12 is approximately 1.45 g/cm³; machined aluminum 6061-T6 is 2.70 g/cm³. Because flexural modulus is lower than aluminum, the cross-section is thickened and internal ribs are added; a gripper finger with a 10 mm square cross-section can support a 2.5 kg payload at 1.5 m/s² acceleration when configured as a cantilever. Threaded brass or stainless steel inserts are installed with heat staking or adhesive bonding. Pull-out force for an M4 brass insert in a 6.0 mm wall is typically in the 120–180 N range, but published data for this specific material is limited. Vacuum channels are printed as internal conduits with diameter 2.0–3.0 mm; channel walls below 1.0 mm are avoided because pressure drop and leakage increase after repeated cycling. The aluminum filler accelerates heat transfer away from contact surfaces, which matters in high-cycle packaging lines where end-of-arm parts contact hot-seal bars at 120–140 °C. Continuous exposure above 130 °C may soften the PA12 matrix; stainless steel thermal shields are recommended when contact time exceeds 2 s. Damping of the polymer matrix reduces peak acceleration spikes at the robot wrist, but vibration amplitude at high-speed moves should be validated with an accelerometer mounted according to ISO 5348:2021. Dimensional checks on printed gripper features follow ISO 1101:2017 for form and position tolerances, with critical mating bores reamed to the final H7 tolerance after sintering.
For subsonic wind tunnel test models, metal-filled polyamide is selected where low mass and internal complexity outweigh the requirement for isotropic aluminum stiffness. The as-built surface is sealed and sanded to a finish of 0.8 µm Ra or better on forward aerodynamic surfaces, which reduces boundary-layer trips caused by layer lines. Pressure taps with diameter 0.5 mm are drilled after printing, and the surrounding wall is reinforced to a minimum thickness of 3.0 mm so that tap insertion does not crack the layer interface. Test models are installed at dynamic pressures up to 2.5 kPa; at higher dynamic pressures, the lower modulus of the material produces measurable wing flex, and published data for DuraForm AF under transonic or supersonic conditions is limited. The aluminum filler raises the heat deflection temperature compared with unfilled PA12, but continuous skin temperature should not exceed 120 °C because the nylon matrix softens and dimensional stability declines. Internal stiffening lattice structures with cell sizes of 4.0–8.0 mm are used to increase bending stiffness without closing off access for pressure tubing. Machined alignment holes are reamed to H7 tolerance, and metal bushings are bonded into load-bearing attachment points. Moisture absorption before testing is controlled by conditioning at 23 ± 2 °C and 50 ± 10 % RH according to ISO 291:2008, since dimensional drift from humidity alters aerodynamic symmetry.
The substitution is viable only when the fixture is loaded in compression or light bending and when the thermal expansion mismatch does not dominate the tolerance stack. Aluminum-filled nylon has a coefficient of linear thermal expansion in the range of 60–90 × 10⁻⁶ K⁻¹; aluminum 6061 is approximately 23.6 × 10⁻⁶ K⁻¹. A locating face with a 200 mm span will shift by 0.07 mm per 10 °C temperature rise if the material sits at the lower end of that range; this must be included in the dimensional capability calculation. Machining after SLS is used on dowel holes, rest pads, and clamping surfaces to achieve flatness within 0.05 mm per 100 mm. Hardened steel bushings are pressed into printed locator bores; direct printed hole edges wear within 500 insertions when loaded by hardened pins. Compressive load capacity is governed by the allowable stress of 30–40 MPa for aluminum-filled PA12 grades; sustained loads above this range cause creep. Fixture bases should bolt into a metal subplate to prevent shop-floor shock loads from cracking the layer interfaces. Chemical exposure limits include cutting fluid concentrates above 5 vol%, concentrated alkaline cleaners above pH 10, and aromatic hydrocarbon cleaning solvents. Dimensional validation follows ISO 1101:2017 on printed features before installation and after first article inspection. For fixture acceptance, critical locators are measured with a coordinate measuring machine and evaluated against the general tolerance class ISO 2768-2 or the drawing-specific datum system.
Aluminum-filled polyamide 12 is used for small-batch electronics enclosures where a cast-metal appearance is required but electroplating is avoided. After vibratory finishing or hand sanding, the surface is sealed and coated with a two-component polyurethane clear coat. The aluminum filler increases heat transfer through the enclosure wall; a 3.0 mm wall under a 10 W internal load reaches steady-state surface temperature approximately 6–10 °C below an unfilled PA12 wall of equal thickness, based on comparative conductive heat-transfer calculations. The material is not a substitute for EMI shielding; even with aluminum filler, the polymer matrix isolates particles and prevents the formation of a continuous conductive network. If shielding is required, an internal nickel-copper coating or conductive gasket must be added. Threaded bosses for M2 and M3 fasteners are designed with a minimum wall thickness of 2.0 mm around heat-staked inserts. Operating temperature is limited to 80 °C continuous for electronic enclosures because thermal cycling above this value accelerates creep at screw bosses. Compliance for general consumer electronics is assessed under IEC 62368-1:2018 for safety and 2011/65/EU RoHS for restricted substances; specific REACH declarations are provided by the powder supplier.
In low-load underhood bracketry, aluminum-filled nylon is direct sintered for wire harness clips, sensor brackets, and HVAC servo housings. The operating environment includes continuous temperatures of 85–105 °C and short excursions to 130 °C; the material retains functional stiffness in this range but creep must be checked at bolt joints. Bosses are designed with embedded steel limiters to prevent joint relaxation. Vibration testing is conducted per ISO 16750-3:2012 for vehicle components; printed brackets should be swept through 10–500 Hz at 3 g root-mean-square acceleration. The nylon matrix absorbs moisture from engine bay humidity, which lowers the glass transition and increases toughness; parts should be conditioned at 23 ± 2 °C and 50 ± 10 % RH per ISO 291:2008 before mechanical validation. Diesel fuel and engine oil resistance is adequate for incidental contact, but continuous immersion in hot ethylene glycol coolant above 90 °C can plasticize the polymer. Threaded fasteners are torqued to 1.2–1.8 N·m for M4 joints when brass limiters are used. Published comparative field data for DuraForm AF in underhood applications is limited; validation should include thermal cycling from −40 °C to 130 °C for 200 cycles and post-cycle torque retention.
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3D Systems DuraForm AF Nylon for SLS Systems is an aluminum-filled polyamide 12 powder designed for selective laser sintering platforms. The product designation is DuraForm AF Plastic; the term DuraForm AF Nylon is used when specifying the nylon 12 matrix chemistry in procurement or process documentation. The material is supplied as a free-flowing powder and sinters into parts with a gray metallic surface appearance. Published manufacturer values list density at 1.26 g/cm³ according to ASTM D792-20, ultimate tensile strength at 48 MPa according to ASTM D638-14, tensile modulus at 4800 MPa, and elongation at break at 1.5%. The powder is applied in functional prototypes, short-run production tooling, assembly jigs, inspection fixtures, and lightweight metal-substitution trials in which elevated stiffness and heat deflection response are prioritized over impact toughness.
The aluminum filler is present as discrete particulate rather than as a continuous metallic phase. This distribution maintains the powder’s dielectric character in most dry conditions but can create local electrical conductivity variation if the filler is not homogeneously dispersed. Powder bulk density is higher than unfilled nylon, and the settled powder weight per unit volume affects dosing and hopper level calibration. Melt flow characterization according to ISO 1133-1:2022 is not a direct measure of SLS processability, but it is used alongside particle size distribution and bulk density to detect contamination or hydrolysis damage in reclaimed powder. A shift in melt flow index of more than 10% from the virgin baseline is generally treated as a process risk on production lines handling filled nylon powders.
Heat deflection temperature data are reported under two stress levels. The published value at 0.45 MPa is approximately 173 °C per ASTM D648-18; the corresponding value at 1.82 MPa is approximately 132 °C. This load-dependent drop reflects the semicrystalline nylon 12 phase rather than the aluminum filler alone. Continuous-use temperature is therefore not equivalent to the 0.45 MPa HDT value. Applications exposed to sustained load above 120 °C require creep testing and long-term heat-resistance evaluation under the actual stress state. On production-scale tooling insert lines, unfilled nylon and polycarbonate fixtures can distort during low-pressure molding operations; aluminum-filled SLS tooling is selected when the printed build envelope can accommodate the required wall stock and when the deflection temperature under low load provides a wider operating window. Published data for long-term thermal aging of this specific product in heated assembly cells remain limited.
The tensile response is stiff and relatively brittle. Flexural modulus is reported as 4500 MPa according to ASTM D790-17, flexural strength as 82 MPa, notched Izod impact as 32 J/m when tested to ASTM D256-10e1, and Shore D hardness as 75 per ASTM D2240-15. The combination of high modulus and low elongation means that snap fits, living hinges, and thin-wall impact features are poor design choices. Machining and tapping are feasible, but thread-forming screws can generate tensile overload at hole edges because the material cannot redistribute stress through plastic deformation. Threaded inserts or through-bolt clamping are preferred on production assembly fixtures. Edge chipping has been observed during drilling operations on wall sections below 1.2 mm, so consumable tooling drills with sharp cutting geometry are recommended. Build orientation should also be evaluated because tensile elongation in the Z axis can be lower than X-Y values due to interlayer adhesion; published data for this specific product’s anisotropic loss is limited, but the effect is sufficiently pronounced that X-Y coupon data alone should not be used to qualify Z-loaded prototypes.
Differential scanning calorimetry of the nylon 12 matrix shows a melting endotherm near 184 °C and a crystallization exotherm near 150 °C according to ASTM D3418-21. The SLS powder bed is maintained between the crystallization onset and the melting peak so that unsintered powder remains free-flowing while the laser supplies only the additional energy required for local fusion. The aluminum filler does not introduce a separate thermal transition in the typical processing window, but it alters the powder bed’s heat-transfer behavior and may shift the effective bed temperature setpoint relative to unfilled nylon. On 3D Systems sPro 60 and sPro 230 platforms, build setup files define the part bed temperature, laser fill power, scan speed, and hatch spacing for this material; machine-specific thermal profiling is required because the metallic filler changes heat dissipation after each layer. If the bed setpoint is too low, large flat tools curl from the perimeter. If the setpoint is too high, the feed region may cake and recoater layers become inhomogeneous.
Laser fill power and scan speed are supplied in material-specific build profiles. The presence of the aluminum filler modifies absorptivity; therefore, unfilled nylon laser settings should not be substituted. Insufficient laser energy produces low interlayer strength and a dull, powdery surface at the part perimeter. Excessive energy causes darkening, excessive melt growth, and loss of fine feature resolution. For feature sizes below 0.5 mm, beam compensation and scan strategy must be validated with test geometries because the melt pool in filled nylon can be wider than in unfilled nylon at the same nominal energy density. Published data for this exact melt pool width on specific SLS machines is limited.
Shrinkage control is addressed through machine-specific scale factors embedded in the build preparation software. The volumetric shrinkage of the nylon 12 matrix during cooling from the sintering temperature to room temperature is influenced by the filler volume fraction; therefore, scale factors for unfilled nylon are not directly transferable to this product. Dimensional accuracy is typically verified against ISO 286 tolerance classes on coordinate measurement equipment. Contact probing force should be kept below 1 N because the low yield strain of the material can produce local indentation in thin sections below 1.0 mm; non-contact optical scanning is preferred for thin-wall geometries.
Moisture control follows nylon 12 SLS powder practice. The product should be stored in a sealed container at relative humidity below 60%. If exposed to humid air or left in an open hopper, drying at 80 °C for 4 to 6 h is typically required before processing. Moisture content above 0.1% can generate porosity, surface defects, and reduced tensile strength in sintered parts because water vaporizes during laser exposure and disrupts the melt pool. Batch-to-batch filler distribution can alter laser absorption; production hoppers are often operated with a 50:50 blend of refreshed and virgin powder to maintain mechanical consistency. Published guidance for this specific grade cautions that excessive reuse without quality inspection can shift the particle size distribution and reduce tensile elongation below the datasheet value. Sieving with a 60 to 80 mesh screen and monitoring melt flow index according to ISO 1133-1:2022 are used on production lines to detect degraded reclaimed powder.
Oxygen exclusion is critical because the powder bed is held at elevated temperature for hours. Oxygen concentrations above 1% promote discoloration and reduce tensile strength through thermo-oxidative degradation of the nylon 12 matrix. Production systems use nitrogen inerting with continuous oxygen monitoring. The aluminum filler can undergo surface oxidation at elevated temperature, but the effect is secondary to matrix degradation if oxygen control fails. In field operation, feed-region caking and build-cake hardness are early indicators of thermal or moisture excursions. A build that requires excessive force to break out may indicate that the powder bed temperature was set too close to the melting peak or that the powder had not been dried. Such process failures are typically detected by comparing the break-out force of the unsintered cake between equivalent builds on the same machine, not by a single absolute value.
Recoater blade wear is more significant with aluminum-filled powder than with unfilled nylon because the metallic filler is harder than the polymer matrix. Production cells using filled powders often inspect recoater edges after 80 to 100 build hours; chipped or worn recoater blades create layer thickness variability and reduce Z-axis tensile strength. Published data for this product’s specific wear coefficient on stainless recoater blades is limited, so the inspection interval should be validated on the target platform.
The aluminum filler produces a density increase and a modulus increase relative to unfilled nylon 12. The following table compares representative published values for the aluminum-filled grade with typical unfilled and glass-filled nylon 12 SLS powders. Values should be verified against current manufacturer technical data sheets because machine, orientation, and powder refresh ratio influence the results.
| Property | Test Method | DuraForm AF Nylon | Unfilled Nylon 12 SLS | Glass-Filled Nylon 12 SLS |
|---|---|---|---|---|
| Density | ASTM D792-20 | 1.26 g/cm³ | 0.95 g/cm³ | 1.25 g/cm³ |
| Tensile modulus | ASTM D638-14 | 4800 MPa | 1600 MPa | 4200 MPa |
| Elongation at break | ASTM D638-14 | 1.5% | 14% | 2% |
| HDT at 0.45 MPa | ASTM D648-18 | 173 °C | 146 °C | 173 °C |
Compared with unfilled nylon 12, the aluminum-filled grade raises tensile modulus by approximately a factor of three and reduces elongation at break to a single-digit value. Compared with glass-filled nylon 12, the aluminum-filled grade offers comparable density and similar low-load HDT, but the metallic filler can provide a different surface appearance and different thermal conductivity characteristics. Published comparative thermal conductivity data for these SLS powders are limited; thermal conductivity should not be assumed to equal bulk aluminum or bulk nylon. In addition, the aluminum-filled product may have higher printed-part density than glass-filled material with the same build time because the filler increases the mass of the powder bed per unit volume, but this also affects recoater wear and powder disposal.
Typical production uses include drill jigs, inspection gages, assembly nests, and low-pressure forming tools. These applications share a common mechanical requirement: high compressive stiffness with low applied tensile stress. In assembly fixtures, the material replaces machined aluminum when the fixture must be produced within a shortened lead time and when the clamping stress is below the material’s low elongation limit. The fixture designer should avoid sharp internal corners because the notch sensitivity of the filled material can initiate brittle fracture. Corner radii of at least 1.5 mm are recommended for features that carry clamping loads; this recommendation is derived from general filled-polyamide design practice rather than a product-specific test standard.
Application selection requires matching the material’s brittle failure mode to the load case. Tooling and fixture applications with compressive loads, low tensile stress, and stable temperatures are appropriate. Components requiring repeated snap assembly, drop impact, or high-torsion fastening should be produced in unfilled nylon or another ductile SLS polymer. Chemical resistance follows nylon 12 behavior; concentrated strong acids, hot alkaline solutions, and prolonged exposure to water above 70 °C can degrade the matrix. REACH and RoHS compliance status should be obtained from supplier documentation for the specific batch, and the material is not certified for food-contact or medical device use unless validated under 21 CFR 177 or ISO 10993 for the intended end-use. Dimensional accuracy of printed parts is typically evaluated against ISO 286 tolerance classes, but the low elongation and anisotropic interlayer bonding require build orientation studies before qualifying production fixtures.
Surface finishing can include bead blasting, abrasive tumbling, and coating. Glass bead blasting at 2.8 to 3.5 bar reduces the granular SLS surface without significant dimensional loss if exposure time is controlled. Solvent-based coatings may attack the polyamide matrix; adhesion should be checked by ASTM D3359-17 cross-cut tape testing before implementation. For tooling surfaces that contact adhesive films or uncured elastomers, release agents can be applied, but compatibility with the release chemistry should be validated because some solvent carriers swell nylon 12. Published data for long-term hot-wet aging, high-cycle fatigue, and ultraviolet exposure of this material remains limited; component approval should therefore be based on end-use testing that includes ASTM D638-14 tensile measurements and ASTM D648-18 thermal deflection measurements, not on room-temperature datasheet values alone.
