Ultrafuse PPSU: Parts That Withstand 180 °C Continuous Use (750 g, 1.75 mm)
Ultrafuse PPSU is a polyphenylsulfone filament from BASF, developed by Forward AM using their Ultrason resin technology. It sits a step above PC, PA, or POM: Forward AM rates it for peaks up to 220 °C and continuous service at 180 °C, with self-extinguishing UL 94 V-0 certification and autoclave sterilization compatibility. Before purchasing, make sure your printer can actually handle what this filament demands — it is not a desktop printer material.
Key Specs
- Material: polyphenylsulfone (PPSU), natural amber color — described as yellow/brown in the datasheet.
- Nozzle: 390–410 °C, bed: 220 °C, actively heated enclosure: 170–210 °C.
- HDT of 215 °C at 0.45 MPa and glass transition temperature of 222 °C (TDS v2.0).
- UL 94 V-0 rated at both 1.5 mm and 3.0 mm thickness, per the manufacturer.
- 750 g spool, 1.75 mm diameter.
Can My Printer Handle This?
Almost certainly not, if you're using a desktop printer. Forward AM requires a nozzle temperature of 390–410 °C, a bed temperature of 220 °C, and an actively heated enclosure running at 170–210 °C. A standard enclosed printer won't reach those numbers — having a shell around the print area isn't enough; the chamber needs real active heating. This is a material for high-temperature industrial machines, and Forward AM only publishes a print profile for Intamsys printers. If your setup doesn't meet all three requirements, check out our technical filaments instead — there are options that work well on conventional enclosed printers.
What Is PPSU Used For?
Forward AM designed this filament for parts that live in high-temperature environments: aerospace and railway components, parts that go through autoclave sterilization at 134 °C with steam, and applications involving continuous contact with hot water, coolants, oils up to 170 °C, fuels, or dishwasher detergents. It is also recommended as a support material for PEI-based filaments such as ULTEM 9085. The flammability data includes passed FAR 25.853 testing (aerospace) at the specified thicknesses, as well as compliance with railway standard EN 45545-2.
Technical Specifications
| Property |
Value |
| Nozzle Temperature |
390–410 °C |
| Bed Temperature |
220 °C (TDS); 200–220 °C per product page |
| Enclosure Temperature |
170–210 °C |
| Build Surface |
Glass |
| Nozzle Size |
≥ 0.4 mm |
| Print Speed |
25–100 mm/s |
| Printed Part Density |
1272 kg/m³ |
| HDT at 1.8 / 0.45 MPa |
211 °C / 215 °C |
| Tensile Strength XY / ZX |
74.5 MPa / 49.0 MPa |
| Flexural Modulus XY / ZX |
1940 MPa / 1700 MPa |
| Flammability Rating |
UL 94 V-0 at 1.5 mm and 3.0 mm |
| Glow Wire (GWEPT) |
960 °C at 1.5 mm and 3.0 mm |
Printing Tips
- Always dry before printing: the manufacturer specifies a vacuum dryer at 125 °C for 8 hours.
- Keep the spool in a sealed container during printing. Bubbles in the melt are a sign of moisture.
- Print on glass. Forward AM notes that Vision Miner's Nano Polymer adhesive improves bed adhesion.
- Work in a well-ventilated space or with active fume extraction, as recommended in the safety datasheet.
Frequently Asked Questions
What temperature can an Ultrafuse PPSU part handle?
According to Forward AM, up to 220 °C for short exposures and 180 °C for continuous service.
Do I need a heated enclosure?
Yes. The manufacturer requires 170–210 °C inside the print chamber, which only high-temperature industrial machines can achieve.
Is it flame retardant?
It is inherently flame retardant, with a UL 94 V-0 rating at 1.5 and 3.0 mm wall thickness per the datasheet. That rating applies to the material tested at those specific thicknesses; you are responsible for validating your final part.
Can it be autoclave sterilized?
Forward AM states it is compatible with steam autoclave sterilization at 134 °C.
Is it food safe?
The manufacturer states it is produced using food-contact-approved raw materials, but the datasheet clarifies that the filament is not FDA approved. For food contact applications, consult your specific use case.
Why isn't it transparent?
Its natural color is amber — yellow/brown — as stated by the manufacturer. This is normal.
How should it be dried?
In a vacuum dryer at 125 °C for 8 hours. Most desktop filament dryers do not reach that temperature, so check yours before use.
What diameter and weight does it come in?
This variant (PPSU-4430a075) is 1.75 mm diameter on a 750 g spool.
