| HS Code | 106689 |
| Product Name | Mitsubishi FGF Recycled PC-ABS 3D Printing Polymer |
| Material Type | Recycled PC-ABS |
| Printing Technology | Fused Granular Fabrication (FGF) |
| Form | Pellets |
| Color | Black |
| Density | 1.15 g/cm³ |
| Tensile Strength | 43 MPa |
| Tensile Modulus | 2100 MPa |
| Flexural Strength | 70 MPa |
| Flexural Modulus | 2200 MPa |
| Elongation At Break | 5% |
| Notched Izod Impact Strength | 100 J/m |
| Heat Deflection Temperature | 105 °C at 1.82 MPa |
| Vicat Softening Temperature | 115 °C |
| Glass Transition Temperature | 125 °C |
| Melt Flow Rate | 10 g/10 min |
| Recycled Content | 100% |
| Printing Temperature | 260-280 °C |
| Bed Temperature | 100-110 °C |
| Drying Conditions | 80 °C for 4 hours |
As an accredited Mitsubishi FGF Recycled PC-ABS 3D Printing Polymer factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Mitsubishi FGF Recycled PC-ABS 3D Printing Polymer is packaged in 25 kg moisture-barrier, foil-lined bags with desiccant and safety labeling. |
| Container Loading (20′ FCL) | 20′ FCL loading: Mitsubishi FGF Recycled PC-ABS 3D Printing Polymer, palletized in bulk bags and secured for safe ocean shipment. |
| Shipping | Mitsubishi FGF Recycled PC-ABS 3D Printing Polymer is shipped as a non-hazardous solid (pellets or filament) in sealed moisture-barrier bags, drums, or boxes on pallets. Keep dry, cool, away from heat, sunlight, and ignition sources. Not regulated for transport; handle with PPE and dispose per local regulations. |
| Storage | Store Mitsubishi FGF Recycled PC-ABS 3D Printing Polymer in a cool, dry, well-ventilated area below 30°C, away from direct sunlight, heat, flames, and strong oxidizers. Keep containers sealed to prevent moisture absorption and contamination. Use original packaging or moisture-barrier bags with desiccant. Avoid prolonged humid air; dry before printing. Maintain clean, labeled, stable shelving and inventory rotation. |
| Shelf Life | Mitsubishi FGF Recycled PC-ABS 3D Printing Polymer shelf life: typically 12–24 months sealed, cool, dry, protected from moisture, heat, UV. |
In low-pressure vacuum forming of PVC and TPO skins for instrument panel topper pads, a cast aluminium plug is frequently substituted with a large-format additive tool produced from Mitsubishi FGF Recycled PC-ABS 3D Printing Polymer. The FGF (fused granular fabrication) pellet feedstock is dried at 80°C for 4 h to reduce moisture below 0.02% by ISO 15512:2019, because residual water in recycled PC-ABS generates splay and layer delamination at the 5 mm extrusion nozzle. The plug is printed as a 12 mm thick shell with 15% triangular infill and a 6 mm outer perimeter count, using a 6 mm nozzle at 2.0 mm layer height and a chamber temperature of 68°C. The printed surface is sealed with a two-component epoxy tooling paste mixed at a 2:1 resin-to-hardener volume ratio and applied at 0.4 mm wet film thickness; after cure the surface is wet-sanded to 600 grit to prevent grain transfer onto the skin. Vacuum channels of 1.5 mm diameter are then drilled at 40 mm center-to-center spacing and chamfered to avoid witness lines. During the forming cycle, TPO sheet is heated to 220°C–260°C radiant surface temperature, while the tool face remains below 65°C because the sheet maintains a 0.8 mm air gap and the tool is water-cooled from the rear. This operating window remains below the heat deflection temperature of recycled PC-ABS, typically 95°C–105°C at 0.45 MPa by ISO 75-2:2013, so creep of the plug is not the governing failure mode. However, if face temperature exceeds 70°C, surface indentation from sheet loading can exceed 0.3 mm after 500 cycles. The terminal output is a vacuum-formed PVC/TPO skin with a Shore A durometer of 60–70 and a wall thickness of 0.8 mm–1.2 mm, later back-foamed with semi-rigid polyurethane. RoHS Directive 2011/65/EU applies because the formed trim enters EU vehicle interiors, and the tooling itself is not sold as an article but remains subject to workplace VOC limits on the epoxy seal coat.
Adhesive layup jigs for bonding chrome-plated ABS trim to door upper rolls require a substrate that tolerates intermittent contact with water-based polyurethane dispersion adhesive and a 3 s open time. The FGF recycled PC-ABS pellet is printed as a 20 mm thick shell with 12% gyroid infill and a 4 mm top skin, using a 3 mm nozzle at 250°C nozzle setpoint and 0.8 mm layer height. Melt temperature measured at the nozzle exit is 238°C, and the part is not annealed after printing. The governing field failure is not layer separation but edge chipping caused by operator collision; therefore the perimeter count is increased to 6 and a 6 mm radius is applied to all external edges. The jig surface is sprayed with a water-based polyurethane release agent after every 200 cycles, and adhesive residue is removed with a 0.5% sodium bicarbonate solution followed by forced air at 60°C. Solvent-based cleaners containing MEK, toluene, or ethyl acetate are incompatible because they soften the PC phase of the blend and cause surface stress cracking. Because the adhesive system contains 2 wt%–5 wt% isopropanol as coalescent, no additional solvent wipe is required before adhesive application. Flexural modulus of a specimen cut from the jig wall is specified in the range 2,100 MPa–2,400 MPa by ISO 178:2019 after conditioning at 23°C and 50% RH for 48 h. The terminal use is a location fixture that holds a door trim substrate within ±0.15 mm while a 1.2 mm bead of adhesive is applied through a robot-mounted nozzle. Published data for this specific recycled FGF grade with an OEM-specific adhesive is limited; a shop-floor trial with the actual adhesive batch is required before substitution.
| Standard or regulation | Test or reported property | Application context |
|---|---|---|
| ISO 527-2:2012 | Tensile strength and tensile modulus | Robot gripper static load envelope |
| ISO 178:2019 | Flexural modulus | Adhesive jig wall rigidity |
| ISO 75-2:2013 | Heat deflection temperature at 0.45 MPa | Vacuum forming plug thermal ceiling |
| ISO 11359-2:2021 | Coefficient of linear thermal expansion | Checking fixture thermal error compensation |
| ISO 4587:2003 | Lap shear strength of bonded joints | Rail vent housing methacrylate joint |
| ASTM D7791-17 | Uniaxial fatigue of plastics | End-of-arm tooling cycle validation |
| REACH Article 33 | SVHC declaration above 0.1% | Imported EU service parts |
| RoHS Directive 2011/65/EU | Restricted substances in homogeneous materials | Vehicle interior tooling residue |
Body-in-white hinge checking fixtures traditionally use 6061-T6 aluminium or granite-touch surfaces. When a replacement printed surface is produced from Mitsubishi FGF Recycled PC-ABS, the design is limited to non-contact datum points or bushings that carry hardened steel inserts, because the PC-ABS substrate is not intended to serve as the final check surface. The fixture body is printed at 0.6 mm layer height with a 2.5 mm nozzle, then bored at 18 mm diameter to accept a hardened steel bushing with a 0.01 mm–0.02 mm interference fit. The bushing carries a 10 mm gauge pin; the PC-ABS body only positions the bushing. Thermal expansion of unfilled recycled PC-ABS is 70 µm/m·K–80 µm/m·K by ISO 11359-2:2021, so a 500 mm span moves 0.017 mm–0.020 mm per °C. A shop floor swing of 5°C therefore produces a positional error of 0.09 mm before electronic compensation. For this reason the fixture is normalized in the metrology room at 20°C ± 1°C for a minimum of 4 h before CMM correlation, and recalibration is required if ambient temperature changes by more than 10°C. The printed substrate is stress-relief annealed at 80°C for 2 h to reduce pocket warpage; no higher temperature is used because deep pockets can distort beyond 0.3 mm per 300 mm flatness after cooling. The terminal product is a checking fixture frame that receives painted or anodized aluminium gauge blocks at each critical hole location. ISO 1101:2017 geometric product specification is used for flatness and perpendicularity of the gauge block seats, while the PC-ABS body is inspected to a flatness of 0.3 mm per 300 mm before metal insert bonding. The fixture is built from 100% recycled FGF pellets without addition of virgin PC/ABS, and no filler is added on the shop floor.
Low-rate replacement of passenger rail ventilation louvers is occasionally evaluated with FGF recycled PC-ABS. The pellet is printed at 0.5 mm layer height with a 2.5 mm nozzle and a chamber temperature of 75°C to suppress delamination of the louver vanes. The as-printed polymer is not flame-retardant; therefore a housing placed inside a passenger compartment does not meet EN 45545-2:2020 R24 HL2 without an intumescent coating. In outside-the-passenger-compartment locations, a two-component water-based intumescent coating of 250 µm dry film thickness is applied after printing. The recycled PC-ABS density is 1.08 g/cm³–1.14 g/cm³ by EN ISO 1183-1:2019, yielding a housing mass of 0.9 kg for a 650 mm × 220 mm assembly. The part is printed in two shells and bonded with a methacrylate structural adhesive mixed at 10:1 by volume and applied at 0.2 mm bond line, cured at 23°C for 24 h. The bond line is the limiting interface, so lap shear strength by ISO 4587:2003 is specified at greater than 6 MPa after 7-day water immersion. Warpage of the unsupported louver span is controlled by a 5% triangular infill located only at the central rib, and the vanes are printed with a 1.0 mm wall thickness to limit air gap variation. The terminal service part is installed with stainless M6 fasteners and 8 mm rubber isolation grommets. Continuous operating temperature above 70°C is not recommended because creep under load may alter the louver gap and reduce airflow calibration. REACH Article 33 declarations are required for any imported EU rail service part containing more than 0.1% of an SVHC, and the recycled feedstock supplier must provide batch-specific declaration.
In high-cycle packaging automation, a robot gripper finger printed from Mitsubishi FGF Recycled PC-ABS replaces a machined acetal component when the environment contains no aggressive ketone washdown agents. The FGF toolpath uses a 1.2 mm nozzle and 0.4 mm layer height to hold a 0.8 mm polished grip surface. The clamping region is printed with 100% infill, while the central web uses 20% triangular infill and a 6 mm top and bottom skin. Pneumatic fittings are threaded directly into printed bosses with 8 mm wall thickness and sealed with PTFE tape; cutting operations are limited to the grip face only, leaving the as-printed ribs in compression. The finger is not exposed to ozone sanitizers or peracetic acid above 2% concentration, because oxidized PC-ABS develops surface microcracks at the bosses. Static load capacity is determined by a three-point bending test on a printed witness coupon using a 50 kN load cell and a crosshead rate of 2 mm/min. Tensile strength and modulus are measured by ISO 527-2:2012; a representative tensile strength of 40 MPa–48 MPa is used to set the initial static load envelope. Published data for dynamic field loading of this specific recycled FGF grade is limited; fatigue behavior is screened by ASTM D7791-17 at 5 Hz and 30% of tensile strength as a conservative initial envelope, and the first article is tested for 500,000 cycles on a pneumatic bench fixture with a 6 N contact load before deployment. The terminal product is a robot end-of-arm gripper that reduces mass from 1.4 kg in aluminium to 0.6 kg in recycled PC-ABS while holding ±0.25 mm over a 350 mm span. Compliance with ISO 12100:2010 machine safety is handled by the integrator; the material supplier's RoHS and REACH declarations cover the feedstock only.
On wind turbine blade manufacturing floors, portable drill templates for root ring inserts are printed as semi-durable guides from Mitsubishi FGF Recycled PC-ABS. A template of 2.4 m diameter is produced in 8 segments. Each segment is printed with a 25 mm wall thickness, 40% gyroid infill, 2 mm layer height, and a 6 mm nozzle on a 3.5 m × 1.5 m gantry FGF system; build time per segment is 18 h. Segment joint faces are machined to a 0.1 mm gap, then bolted together with stainless M8 fasteners and 0.1 mm steel shims to correct cumulative radial error. The root holes are 22 mm diameter; the PC-ABS template is fitted with hardened steel drill bushings of 22 mm ID using a 0.02 mm press fit. Because the shop floor temperature ranges from 15°C to 30°C and the template is not used in a heated autoclave, thermal expansion remains within the laser tracker tolerance band. Vacuum hold-down grooves are printed in the base at 3 mm depth and sealed with a 1 mm silicone gasket to stabilize the template on the blade root face. The template is used with dry drilling only; if cutting fluid is required, the PC-ABS surface must be protected by a 50 µm PTFE film because emulsified oil can penetrate layer lines and cause swelling. The terminal output is a drilled wind blade root with hole positional deviation below 0.5 mm over a 2.4 m pitch circle, verified by laser tracker. The template is not a delivered article; material declarations follow REACH and RoHS Directive 2011/65/EU for the supplied pellet.
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Among large-format additive manufacturing feedstocks, Mitsubishi FGF Recycled PC-ABS 3D Printing Polymer is a granulate-form polycarbonate/acrylonitrile-butadiene-styrene blend compounded from reclaimed streams for screw-driven fused granular fabrication. The product is differentiated from filament-grade recycled PC-ABS by its direct-feed format, which removes filament diameter tolerance as a process variable but shifts control burden to granulate size distribution, drying, and hopper flow. Published technical data for this specific recycled configuration is limited; processing and property windows should therefore be established from the manufacturer’s certificate of analysis and first-article qualification rather than transferred directly from neat PC-ABS datasheets. The material is intended for large-format jigs, fixtures, thermoforming aids, prototype interior trim, and low-rate production tooling where moderate thermal resistance and impact toughness are required.
Processing of PC-ABS class materials through screw-driven fused granular fabrication operates within a narrower melt-temperature band than unreinforced ABS. Published large-format equipment logs for recycled PC-ABS cite segmented barrel setpoints from 240 °C to 270 °C from feed throat to metering section, with nozzle setpoints between 260 °C and 280 °C. A heated chamber maintained at 60 °C to 90 °C and a build plate at 100 °C to 120 °C reduce warpage caused by differential shrinkage between the deposited layer and the already cooled substrate. Processing above 290 °C should be avoided because the butadiene phase in the ABS fraction degrades, producing color shift, surface exudate, and loss of impact strength. The melt residence time at processing temperature should not exceed 10 min in the barrel; longer residence times have been associated with cross-linking or chain scission in recycled PC-ABS feedstocks. Melt-pressure oscillation at the nozzle exceeding ±15% of the stabilized value indicates feed surging or partial nozzle blockage and requires immediate hopper or barrel inspection.
Before printing, the granulate requires drying in a desiccant dryer with a dew point of −40 °C or lower. Moisture levels above 0.02% by weight, as determined by Karl Fischer titration according to ISO 15512:2019, generate splay, interlayer porosity, and hydrolysis-induced molecular weight loss in the PC phase during extrusion. A drying cycle of 80 °C to 100 °C for 4 h to 8 h is typical for the PC-ABS class, but recycled lots with higher surface area or densified flake may require 6 h to 12 h. Drying hoppers should be inert-gas blanketed when ambient relative humidity exceeds 60% to prevent moisture re-uptake during extended campaigns exceeding 24 h. Failure to maintain the specified moisture limit typically appears first as a drop in Z-axis tensile strength, because hydrolysis products depress interlayer diffusion at the weld interface.
Selection of this material over virgin PC usually occurs when lower melt temperature and reduced tendency for nozzle freeze-off are more important than maximum heat deflection. Selection over ABS occurs when higher notched impact resistance and higher heat deflection temperature are required for fixture durability. Under short-term load, unfilled recycled PC-ABS class materials typically exhibit HDT/A 1.8 MPa values in the 96 °C to 110 °C range when tested according to ISO 75-2:2013 method A. By comparison, unfilled ABS class materials commonly fall between 85 °C and 100 °C, while unfilled PC class materials exceed 125 °C. These temperature envelopes matter in paint cure fixtures, thermoforming tools, and welding jigs where tool surfaces see intermittent radiant or conduction heat. For continuous service above 110 °C, the printed PC-ABS should be stress-relieved by annealing at 80 °C to 90 °C for 2 h to 4 h; otherwise built-in residual stress from layer deposition accelerates creep and warpage. The material is not a direct substitute for high-temperature tooling polymers such as polyethersulfone or polyetherimide when service temperatures exceed 130 °C.
Because the recycled PC-ABS grade is supplied as granulate rather than filament, its mechanical properties are controlled by both the compounded feedstock and the deposition parameters. The following table compiles representative unfilled polymer class ranges from ISO and ASTM datasheet literature. The table is a screening matrix and is not a substitute for lot-specific mechanical testing.
| Property | Test method | Recycled PC-ABS class | ABS class | PC class |
|---|---|---|---|---|
| Tensile yield stress | ISO 527-2 | 45–60 MPa | 35–50 MPa | 60–70 MPa |
| Tensile modulus | ISO 527-2 | 2.0–2.6 GPa | 1.8–2.5 GPa | 2.1–2.4 GPa |
| Flexural modulus | ISO 178 | 2.0–2.7 GPa | 1.7–2.5 GPa | 2.2–2.5 GPa |
| HDT/A at 1.8 MPa | ISO 75-2 | 96–110 °C | 85–100 °C | 125–140 °C |
| Notched Izod impact at 23 °C | ISO 180/A | 30–65 kJ/m² | 15–35 kJ/m² | 60–90 kJ/m² |
Published data for the specific recycled Mitsubishi configuration is limited; lot certificates may report Charpy notched impact according to ISO 179-1 or Izod according to ISO 180/A. Because fused granular fabrication builds parts through successive weld lines, tensile and impact values are not isotropic. Published studies on large-format PC-ABS report that Z-direction tensile strength is 30% to 60% lower than XY tensile strength, depending on chamber temperature, layer height, and nozzle diameter. Layer heights between 0.3 mm and 0.8 mm with a nozzle diameter of 1.5 mm to 2.0 mm produce measurable differences in void content. For structural parts, ASTM D638-14 tensile specimens should be machined from printed blanks in both XY and Z orientations. Impact specimens per ISO 179-1 or ISO 180/A should be notched after printing to avoid introducing machining artifacts into the fracture plane.
Recycled content claims require chain-of-custody documentation or a mass-balance certificate. For products sold in the European Union, compliance with REACH and the restriction of hazardous substances under RoHS 2011/65/EU should be verified from the supplier’s declaration. The polymer is not automatically food-contact approved; absence of specific migration limits under EU 10/2011 should be confirmed before use in food-contact tools. Flammability classification is not implicit in recycled PC-ABS without flame retardant additives; unfilled PC-ABS class materials are usually rated UL 94 HB when tested according to IEC 60695-11-10. A V-0 rating should not be assumed for this recycled grade unless explicitly stated on the lot certificate. Electrical and electronic applications requiring glow-wire performance to IEC 60695-2-11 must be qualified separately because recycled lot composition can shift the ignition and flammability response.
On production-scale large-format machines with screw barrel L/D ratios between 20:1 and 30:1, recycled PC-ABS has shown two recurrent failure modes: granulate bridging in the feed throat when particle size distribution contains excessive fines below 1 mm, and melt viscosity shifts when regrind content or moisture deviates from the drying specification. A rotary hopper feeder or pneumatic agitator is specified in documented service bureau operating procedures for recycled granulate to maintain constant metering. Barrel residence volume purging between material changes should equal 2 to 5 times the barrel volume, especially when transitioning from lower-temperature ABS to PC-ABS to remove degraded polymer from dead zones. Lot-to-lot melt flow variation is the most significant quality risk for recycled PC-ABS. Melt volume-flow rate determined by ISO 1133-1:2022 at 260 °C under 5 kg can vary by more than ±20% across recycled lots if post-consumer content is not balanced with prime resin during compounding. A pre-production capillary rheometry sweep from 100 s⁻¹ to 1000 s⁻¹ at 260 °C is used to establish the shear-thinning envelope for each lot before locking extrusion parameters. Lower melt viscosity lots generate excessive ooze during non-extruding moves; higher viscosity lots raise melt pressure and reduce deposition rate on machines without closed-loop pressure control. When the recycled fraction exceeds 50%, the use of a melt pump after the extruder is documented on some large-format lines to dampen flow variation.
Thermal degradation in recycled PC-ABS is primarily controlled by the unsaturated butadiene segments in the ABS component. Above 280 °C, oxidative degradation of the butadiene phase can proceed rapidly, releasing volatile by-products and darkening the melt. The PC phase is more resistant but undergoes hydrolytic chain scission if moisture is not removed. Exclusion of oxygen through nitrogen blanketing of the hopper and barrel feed zone slows oxidative degradation but does not eliminate residence-time limits. For parts requiring post-print annealing, the temperature should remain below the HDT/A of the material; annealing above 110 °C can distort unsupported walls and relieve residual stress unevenly. In applications involving high-temperature exposure, creep modulus and notched impact retention should be evaluated according to ISO 899-1 and ISO 180/A after conditioning at the intended service temperature for 168 h.
For comparison against filament-based recycled PC-ABS grades, the principal differences are feed geometry, deposition rate, and process control. Filament grades require diameter control within ±0.05 mm; granulate feed eliminates continuous diameter measurement but shifts the burden to pellet size uniformity and drying. FGF deposition rates on nozzle diameters of 1.2 mm to 3.0 mm can exceed 1 kg/h on large-format machines, whereas filament extrusion rarely exceeds 0.2 kg/h on similar gantry platforms. Compared with carbon-fiber-filled recycled polyamide 6, PC-ABS exhibits lower moisture sensitivity and lower modulus but higher impact strength. Compared with recycled PETG, PC-ABS offers higher HDT/A but requires higher chamber and bed temperatures. Compared with virgin PC-ABS of the same hard-segment ratio, the recycled product may exhibit a broader melting range, lower zero-shear viscosity, and reduced notched impact because the reclaimed fraction contains oxidative degradation residue from prior heat history. Differential scanning calorimetry per ISO 11357 can reveal a broader glass transition around 105 °C to 115 °C in the PC phase, but this is not a specification.
At the operational boundary, chemical exposure defines the service limit. The material is vulnerable to stress cracking in the presence of ketones, esters, aromatic hydrocarbons, and some cutting fluids; compatibility should be screened according to ISO 22088-3 using the intended service fluid at the maximum service temperature. Continuous immersion is not recommended without evaluation. Outdoor weathering without UV-stabilized cap layers leads to embrittlement of the butadiene phase; if outdoor use is required, accelerated weathering per ISO 4892-2 should be conducted to establish color and impact retention. The material is not recommended for direct skin contact or food-contact applications without specific migration testing. Injection molding-grade virgin PC-ABS data cannot be transferred directly to fused granular fabrication parts because layer-boundary porosity and anisotropic morphology alter the measured mechanical response. Manufacturing aids for composite layup and paint masking are selected when the printed tool must survive repeated cycles at 80 °C without creep. In such service, the HDT/A envelope of 96 °C to 110 °C provides a margin, provided that the fixture is not under continuous clamp load. For low-volume automotive interior trim prototypes, the material is used as an alternative to milled ABS or polyurethane board because it can be printed in large sections and post-machined to a smooth surface. The recycled content does not alter the need for surface sealing before painting; solvent-borne coatings should be screened for compatibility with the PC phase.
