PPS CF

PPS CF (carbon fibre-reinforced polyphenylene sulphide) is a high-performance thermoplastic designed for technical and industrial applications requiring superior thermal stability, rigidity, and mechanical strength. The presence of carbon fibre provides an excellent strength-to-weight ratio while reducing deformation and warping during printing. Thanks to its semi-crystalline structure and the inherent chemical stability of PPS, this composite offers reliable performance in harsh environments where many other polymers fail.

In 3D printing (FDM), PPS CF represents a premium choice for functional parts operating at high temperatures or under mechanical stress. However, like all technical materials, it has both advantages and limitations that must be considered during design.

Advantages of PPS CF

The primary strength of PPS CF lies in its outstanding thermal stability: its HDT reaches 250 °C at 0.45 MPa and up to 255 °C after annealing. Even under higher loads (1.8 MPa), the material maintains an HDT of 125–150 °C, well above standard engineering polymers. This enables PPS CF to operate continuously at very high temperatures without loss of rigidity or deformation.

Mechanically, the material exhibits a flexural strength of 138 MPa, a flexural modulus of 6000 MPa, and a tensile strength of 74 MPa. Combined with a density of only 1.34 g/cm³, it offers excellent stiffness-to-weight performance, ideal for high-performance structural components.

The carbon fibre reinforcement also reduces shrinkage and improves dimensional stability, ensuring precision and tight tolerances even in complex parts. It is chemically resistant, inherently flame retardant (UL94 HB), and compliant with REACH and RoHS directives—making it suitable for demanding industrial and technical environments.

Disadvantages

As is typical for high-performance materials, PPS CF’s advantages come with some trade-offs. Its impact toughness is moderate (notched Izod value around 5.5 kJ/m²), which may make it more brittle than polymers such as PA or PC, especially in thin sections or stress-concentrated geometries.

Moreover, PPS CF is rated UL94 HB rather than V-0, meaning it is not recommended for applications requiring strict self-extinguishing behaviour or electrical safety certifications.

From a processing perspective, PPS CF requires high extrusion temperatures (290–315 °C), a heated bed (80–90 °C), and pre-drying at 120–130 °C for 3–4 hours to prevent moisture-related printing defects. This necessitates professional-grade printers capable of handling high-temperature materials. Finally, it is not food-safe, limiting its use in medical or food-tech applications.

Applications

PPS CF is ideal for structural and functional parts exposed to extreme thermal conditions, such as industrial machinery components, electric motor mounts, hot-zone sensor housings, or tooling elements subject to mechanical and thermal stress.

Its dimensional stability and rigidity make it perfect for jigs, fixtures, and work-holding tools that must retain precision even after repeated thermal cycles.

It is also valued in electrical and electronic applications, where the combination of rigidity, chemical resistance, and dimensional stability ensures long-term reliability. In harsh or chemically active industrial environments, the PPS matrix provides excellent resistance to solvents, oils, and hydrocarbons, ensuring durability even in the presence of corrosive agents.

Comparison with other FDM materials

Compared with other engineering materials for FDM printing, PPS CF is in the middle range between advanced engineering polymers and super-polymers, offering an excellent compromise between performance and processability.

• PA-CF (carbon-filled nylon): PPS CF clearly outperforms in thermal stability and deformation resistance. Nylon, though tougher and easier to print, is highly moisture-sensitive and has an HDT over 100 °C lower. In hot or humid conditions, PPS CF maintains its shape and performance far better.

• PC or PC-CF: Reinforced polycarbonates offer good toughness and moderate heat resistance (up to 120–140 °C), but cannot match the thermal performance of PPS CF. PPS CF is also more chemically stable and less prone to long-term thermal deformation.

• PEEK or PEEK-CF: These super-polymers deliver the highest mechanical and thermal performance (HDT > 300 °C), but at significantly higher cost and processing complexity. PPS CF offers a more accessible alternative, covering many industrial needs without the drawbacks of PAEK-class polymers.

• Reinforced ABS or PETG: PPS CF vastly outperforms these in stiffness, HDT, and chemical resistance. However, ABS and PETG remain preferable for non-structural parts, prototypes, or cost-sensitive applications.

In summary, PPS CF occupies a middle ground between conventional engineering plastics and super-polymers, offering an excellent balance between performance and processability for industrial-grade printers.

Conclusion

PPS CF stands out as a high-performance material for functional and technical applications, capable of maintaining rigidity and dimensional stability even at very high temperatures. Its combination of high modulus, low density, and chemical resistance makes it an excellent choice for mechanical, structural, and industrial components.

Although it requires demanding printing conditions and attention to impact strength and environmental compatibility, PPS CF remains a benchmark polymer for high-temperature use. It represents a cost-effective, accessible alternative to ultra-high-performance materials such as PEEK, while being far more robust and stable than filled nylons or polycarbonates.

In conclusion, PPS CF is the ideal choice for those seeking lightweight, rigid, and dimensionally stable components designed to withstand prolonged exposure to thermal and mechanical stress.