Zortrax Endureal flame retardant railway

Zortrax’s BASF flame-retardant PPSU filament gains railway certification

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The Zortrax Endureal 3D printer is now compatible with a flame-retardant BASF Ultrafuse PPSU filament, certified for use in railway industry, due to its resistance to fire and chemicals, opening it to hydraulic and aerospace applications also.

PPSU belongs to the group of polysulfones, which are high-performance engineering thermoplastics known for very good performance in extreme thermal conditions. One of the most important characteristics of Ultrafuse PPSU is its inherent fire resistance.

The flame-retardant filament complies with the EN 45545-2 railway classification and has been approved for use in manufacturing of rail vehicles operating both on the surface and underground.

The material also complies with the UL 94 norm and has a V0 rating, meaning end-use components reduce the risk of spreading fire in a vehicle in case of an emergency.

Zortrax Endureal flame-retardant railway grab handleLaunched as part of Zortrax’s long-term cooperation with BASF Forward AM for the Endureal, BASF Ultrafuse PPSU filament joins materials like ABS, ULTRAT,BASF, Ultrafuse PC/ABS FR, plus high performance PEEK, PEI and PAEK.

“This 3D printing filament passed numerous fire tests in line with the European railway standard, ensuring it is safe to manufacture such components as air ducts on locomotives, flaps, grilles, or streamlining parts,” explained Daniel Dudenko, senior 3D Printing tester at Zortrax’s R&D centre.

“These all can be successfully 3D printed on Zortrax Endureal with PPSU, provided the filament is dried properly before use, and the printer’s build platform is covered with Magigoo HT adhesive.”


The newly introduced material is also characterised by being able to retain its properties and geometry when exposed to high temperatures and steam, while showing high resistance to oils, fluorine, coolants, lubricants, and fuels.

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