Fire safety is a top priority in industries like aerospace, medical, automotive, and industrial manufacturing. When designing plastic components for these applications, selecting flame-retardant (FR) materials is essential to ensure compliance with safety regulations and minimize fire hazards. However, the manufacturing process used to shape these materials plays a crucial role in determining the final product’s durability, precision, and fire resistance.
This guide explores the three primary manufacturing methods for FR plastics—3D printing, thermoforming, and machining—and highlights the best materials for each process.
Understanding Flame-Retardant Plastics
Flame-retardant plastics are engineered to resist ignition, self-extinguish when exposed to flames, and reduce smoke and toxic emissions. Many industries require materials that meet UL 94 V-0 standards, ensuring that plastics self-extinguish within 10 seconds without dripping flaming particles. The choice of both the material and manufacturing process can impact how well these plastics perform in fire-critical environments.
3D Printing: Custom, Complex, and Lightweight FR Parts
Why Choose 3D Printing?
3D printing, also known as additive manufacturing, allows for highly detailed, lightweight, and complex geometries that would be difficult or impossible to create using traditional manufacturing. This makes it an excellent choice for prototyping, aerospace, medical, and electronic applications where weight reduction and rapid production are priorities.
Best Flame-Retardant Plastics for 3D Printing
- ULTEM™ 9085 (FDM – Filament Extrusion)
- Strengths: High mechanical strength, lightweight, and excellent chemical resistance
- Flame Resistance: Meets UL 94 V-0 and aerospace FST (Flame, Smoke, and Toxicity) standards
- Ideal For: Aircraft interiors, automotive parts, and industrial enclosures
- xPro 9400 B FR (SLA/DLP – Photopolymer Resin)
- Strengths: High resolution, smooth surface finish, and fast production speed
- Flame Resistance: UL 94 V-0 rated at a 2mm thickness
- Ideal For: Electronic housings, detailed prototypes, and non-load-bearing industrial components
Limitations of 3D Printing FR Plastics
- FDM-printed parts may have lower mechanical strength compared to machined or thermoformed components.
- SLA/DLP resins may be brittle and not suitable for load-bearing applications.
Thermoforming: Scalable and Cost-Effective for Large FR Parts
Why Choose Thermoforming?
Thermoforming is a highly scalable process used for manufacturing thin-walled, large plastic components such as enclosures, panels, and housings. It is a preferred method in aerospace, public transportation, and medical applications because of its lightweight construction and impact resistance.
Best Flame-Retardant Plastics for Thermoforming
- Kydex (Acrylic-PVC Alloy)
- Strengths: High impact strength, chemical resistance, and ease of forming
- Flame Resistance: UL 94 V-0 rated
- Ideal For: Aircraft interiors, medical enclosures, and public transportation panels
- Boltaron 4335 (Extruded Thermoplastic Sheet)
- Strengths: Superior chemical and abrasion resistance
- Flame Resistance: UL 94 V-0 rated, non-hygroscopic (does not absorb moisture)
- Ideal For: Aerospace panels, medical trays, and industrial equipment housings
- Royalite R57 (ABS/PVC Blend)
- Strengths: Rigid structure with a smooth surface finish
- Flame Resistance: UL 94 V-0 rated
- Ideal For: Automotive interior panels, medical and industrial housings
- Flame-Retardant Polycarbonate (TUFFAK® F)
- Strengths: Transparent, high-impact resistance, and excellent heat resistance
- Flame Resistance: UL 94 V-0 rated
- Ideal For: Safety shields, medical barriers, and machine guards
Limitations of Thermoforming FR Plastics
- Requires pre-made molds, increasing initial setup costs.
- Less suitable for small, complex parts with intricate internal geometries.
Machining: Precision and Strength for High-Performance FR Parts
Why Choose Machining?
Machining is the best method for manufacturing high-strength, tight-tolerance parts from solid plastic blocks. Unlike thermoforming or 3D printing, machining retains full material integrity, making it ideal for aerospace, medical, semiconductor, and industrial components.
Best Flame-Retardant Plastics for Machining
- Flame-Retardant Polycarbonate (PC)
- Strengths: High impact strength, optical clarity, and excellent dimensional stability
- Flame Resistance: UL 94 V-0 rated
- Ideal For: Protective shields, machine enclosures, and safety equipment
- Flame-Retardant Acetal (POM)
- Strengths: Low friction, high stiffness, and wear resistance
- Flame Resistance: UL 94 V-0 rated
- Ideal For: Gears, bearings, sliding components, and mechanical parts
- Flame-Retardant PVDF (Kynar 740)
- Strengths: Superior chemical and heat resistance, excellent electrical insulation
- Flame Resistance: UL 94 V-0 rated
- Ideal For: Semiconductor processing components, chemical storage tanks, and high-voltage insulators
Limitations of Machining FR Plastics
- Generates higher material waste than thermoforming.
- Not cost-effective for large-scale production.
Choosing the Right FR Plastic and Process for Your Application
- For complex, lightweight designs, 3D printing offers rapid prototyping and customization.
- For large, thin-walled components, thermoforming provides an efficient, cost-effective solution.
- For high-strength, precision components, machining ensures tight tolerances and durability.
By selecting the right flame-retardant plastic and manufacturing process, industries can improve fire safety while maintaining performance and compliance with regulatory standards.
Work with Experts in Flame-Retardant Plastics
At RapidMade, we specialize in manufacturing custom flame-retardant components using 3D printing, thermoforming, and machining. Our team works with high-performance UL 94 V-0 materials to ensure compliance with aerospace, medical, and industrial safety regulations.
To learn more about how we can support your project, visit RapidMade.com.
IQ Newswire 
Kieran