PSU FILAMENT • 3DXTECH • REV1 TECH
3DXTech ThermaX™ PSU Polysulfone — 190°C Tg · ULTEM 9085 Alternative · Made in USA
Polysulfone — 190°C Tg · ULTEM 9085 Alternative · Made in USA
3DXTech’s ThermaX PSU delivers the thermal stability and hydrolytic resistance of the sulfone polymer family at an accessible price point. With a 190°C Tg, inherent UL 94 V-0 flame resistance, and outstanding ESCR (Environmental Stress Crack Resistance), PSU is a cost-effective alternative to ULTEM 9085 for applications requiring high-temperature performance without the premium cost of PAEK-class materials.
Lead time varies. Contact Rev1 to confirm availability.
WHY PSU
190°C Tg. ULTEM 9085 Alternative. Inherent UL 94 V-0.
ThermaX™ PSU is 3DXTech’s polysulfone filament — delivering cost-effective high-temperature performance with inherent UL 94 V-0 flame resistance, outstanding hydrolytic stability, and excellent ESCR for demanding fluid-contact applications.
ULTEM 9085 Alternative
190°C Tg surpasses ULTEM 9085 (186°C) while offering a lower entry cost. Outstanding ESCR and hydrolytic stability for demanding fluid-contact applications.
Inherent UL 94 V-0
Flame resistance is built into the polysulfone backbone — no additives. Low smoke evolution for aerospace, automotive, and enclosed-space applications.
Natural & Black Colors
Available in natural and black from 250g starter rolls to 500g production spools. Black color ideal for UV-stable or stealth-appearance components.
Made in USA
Produced in-house at 3DXTech’s Grand Rapids, MI facility under ISO 9001:2015 certification. Lot traceability and process controls throughout.
PRINTING WITH PSU
PSU — Polysulfone for Cost-Sensitive High-Performance Applications
ThermaX PSU is not a plug-and-print material. It requires industrial hardware and process discipline — a heated chamber and all-metal hot end rated to 400°C+. Follow this protocol for consistent results.
- Extruder Temp 350–380°C — all-metal hot end required
- Bed Temp 140–160°C — PEI or garolite build surface
- Chamber Temp ≥70°C recommended — heated enclosure strongly recommended
- Nozzle All-metal, stainless or hardened steel — ≥0.4mm diameter
- Drying 120°C / 4 hr minimum before every print session
- ⚠ End-of-Session Purge nozzle completely before cooling. Residual PSU can degrade in the melt zone if left to cool — always purge fully before shutdown.
THERMAL DATA
190°C Tg with Excellent ESCR and Hydrolytic Stability
Four thermal milestones that define ThermaX™ PSU’s operating envelope — verified against 3DXTech ThermaX PSU Technical Data Sheet v1.
190°C Tg with excellent ESCR and hydrolytic stability — exceeding ULTEM 9085 (186°C Tg) while offering a more accessible price point. PSU maintains structural integrity in hot water contact and steam environments where standard engineering plastics fail.
HDT at 0.45 MPa. Structural load-bearing capability well above standard service temperatures, with hydrolytic stability through hot water and steam environments.
Sustained continuous-use temperature under structural load. For short-term peak exposure, the 185°C HDT and 190°C Tg define the practical upper ceiling.
Required before every session. PSU is hygroscopic — even trace moisture causes bubble defects and weakened layer adhesion at 350–380°C extrusion temps. Print from the dryer.
CHEMICAL RESISTANCE
High ESCR — Resistant to Chemical Attack Under Stress
ThermaX™ PSU’s amorphous polysulfone backbone resists a broad range of chemicals — including automotive fluids, hydrocarbons, alcohols, and aqueous process streams. The sulfone backbone delivers exceptional Environmental Stress Crack Resistance (ESCR), critical when stressed parts contact solvents or cleaning agents.
Consult TDS for complete chemical compatibility data before use in fluid-contact applications.
SPECIFICATIONS
ThermaX™ PSU — Full Technical Data
Source: 3DXTech ThermaX™ PSU TDS v1. Specifications at 1.75mm diameter, natural color.
Material Properties
| Polymer | Polysulfone (PSU) |
| Diameter | 1.75mm |
| Color | Natural, Black |
| Glass Transition (Tg) | 190°C |
| Heat Deflection (HDT) | 185°C |
| Continuous Use Temp | 160°C |
| Flame Rating | UL 94 V-0 (inherent, no additives) |
| Tensile Strength | 70 MPa (ASTM D638) |
| Flexural Strength | 120 MPa (ASTM D790) |
| Tensile Elongation | 12% |
| Density | 1.24 g/cm³ |
Print Parameters
| Extruder Temp | 350–380°C |
| Bed Temp | 140–160°C |
| Chamber Temp | ≥70°C (recommended) |
| Drying Protocol | 120°C / 4 hr minimum |
| Min. Layer Height | 0.10mm |
| Nozzle Type | All-metal (stainless or hardened steel) |
| Min. Nozzle Diameter | 0.4mm |
| Hot End Requirement | All-metal, rated ≥400°C |
Availability & Pricing
| Spool Sizes | 250g, 500g |
| Colors | Natural (250g, 500g), Black (500g) |
| 250g Price | $70 |
| 500g Price | $125 |
| Lead Time | Varies — contact Rev1 to confirm |
| Quality Standard | ISO 9001:2015 Certified |
| Origin | Grand Rapids, MI, USA |
SPOOL SELECTION
250g & 500g — Natural and Black.
ThermaX™ PSU is available in 250g natural, 500g natural, and 500g black. For volume requirements, contact Rev1 Tech for availability.
- Reel #1 — 165mm dia.
- Color: Natural
- Polysulfone (PSU)
- Reel #2–#7 — 198mm dia.
- Color: Natural
- Polysulfone (PSU)
- Reel #2–#7 — 198mm dia.
- Color: Black
- Polysulfone (PSU)
PRINT QUALITY
Production-Grade Output on the Right Equipment
ThermaX™ PSU produces parts with excellent surface detail and strong interlayer adhesion when printed on a properly configured industrial platform with an all-metal hot end and heated chamber.
COMPATIBLE PLATFORMS
Requires an Industrial-Grade 3D Printer
ThermaX™ PSU demands an all-metal hot end rated to at least 400°C and an actively heated enclosure (≥70°C). Beyond consumer hardware, but accessible to any purpose-built industrial platform.
CreatBot F160-PEEK
Purpose-built PAEK platform with dual all-metal hot ends and integrated chamber heating. Validated for PSU and PEEK — Rev1’s top recommendation for first-time ultra-performance adopters.
Rev1 RecommendedCreatBot PEEK-300
300mm build volume, 420°C hot end rating, 200°C heated chamber. Production-oriented PAEK platform suitable for PSU at larger part geometries.
Rev1 RecommendedCreatBot F430
Quad-nozzle large-format industrial printer with multi-material capability. Supports PSU plus support materials for complex geometries and dual-extrusion workflows.
Rev1 RecommendedAny Open-Platform Printer
Minimum: 400°C+ all-metal hot end • 120–160°C heated bed • ≥70°C enclosure • all-metal nozzle ≥0.4mm.
WHERE IT WORKS
Six Industries Where Thermal Stability, Flame Resistance, and Cost Efficiency Converge
When inherent UL 94 V-0, 190°C Tg, hydrolytic stability, and cost-effective performance must coexist — ThermaX™ PSU is the answer.
Aerospace
Interior structural components, bracket assemblies, and ducting requiring inherent flame resistance, low smoke, and moderate high-temperature performance.
Medical
Device housings, surgical instrument components, and sterilization-compatible tooling. PSU offers autoclaveability with excellent dimensional stability.
Fluid Handling
Pump housings, valve bodies, manifolds, and pipe fittings for hot water, chemical process fluids, and industrial cleaning agent contact.
Automotive
Sensor housings, fluid contact brackets, and under-hood components with good chemical resistance to automotive fluids.
Electronics
Stable dielectric properties, inherent flame resistance, and high thermal capability for power electronics enclosures.
Industrial
High-temperature fixture tooling and process equipment where cost-effectiveness is required alongside good thermal performance.
MATERIAL CARE
Moisture Is the Enemy. A Proper Protocol Eliminates It.
PSU is hygroscopic and absorbs moisture readily. Printing with undried filament at 350–380°C produces bubbling, rough surfaces, and weakened layer adhesion. Follow this protocol every session.
Dry Before Every Session
120°C minimum / 4 hours minimum. No exceptions — even a sealed spool that has been open for a few days benefits from a fresh drying cycle.
Print From the Dryer
For best results, print directly from a heated dry-box or dryer system. Ambient humidity will re-absorb into the filament during extended print runs.
Store Sealed With Desiccant
Return unused filament to an airtight bag or container with fresh desiccant immediately after printing. Long-term storage in original sealed packaging is acceptable.
Recognize Wet Filament Symptoms
Popping or crackling during extrusion, rough surface texture, reduced layer adhesion, and visible bubbling in the melt are signs of moisture contamination. Re-dry and restart.
HOW IT COMPARES
ThermaX™ PSU vs. Commonly Evaluated Alternatives
Buyers evaluating PSU typically compare against ThermaX PPSU for higher Tg and toughness, ThermaX PEI 9085 for an ULTEM-class comparison, and ThermaX PEI 1010 for the higher-Tg PEI option.
3DXTech / Rev1 Tech
3DXTech
3DXTech
3DXTech
3DXTECH QUALITY
Manufactured in Michigan. Certified to ISO 9001:2015.
Every spool of ThermaX™ PSU is produced in-house at 3DXTech’s Grand Rapids, MI facility under ISO 9001:2015 certification. Polysulfone resin with inherent UL 94 V-0 and full lot traceability throughout filament fabrication.
ISO 9001:2015 Certified
Production under a certified quality management system. Lot traceability and process controls throughout filament fabrication.
Made in Grand Rapids, MI
Filament extruded and wound in-house at 3DXTech’s Michigan facility. Direct factory quality control — not overseas commodity production.
Technical Data Sheet Available
Full processing parameters, mechanical properties, UL 94 V-0 compliance data, and chemical resistance published in the ThermaX™ PSU TDS v1. Available for download below.
RESOURCES
Downloads & Technical Support
Everything you need to qualify and print ThermaX™ PSU with confidence. UL 94 V-0 compliance data, processing parameters, and technical support from Rev1.
WHY REV1 TECH
Authorized 3DXTech Reseller. Industrial AM Specialists.
Rev1 Technologies is an authorized 3DXTech reseller headquartered in Auburn Hills, MI, with direct technical expertise in high-performance FFF materials and the printers that run them.
Authorized Reseller
Every spool ships direct from the authorized channel. MAP pricing guaranteed. Single-channel license compliance — not a grey-market distributor.
Platform Expertise
Rev1 carries the industrial printers validated for PSU and PEEK. If you need guidance on which platform to match with this material, our team has run them.
Pre-Sales Technical Support
Questions about print settings, printer selection, or qualifying PSU for a specific application? Contact Rev1 before you order — that conversation is free.
FREQUENTLY ASKED
ThermaX™ PSU — Buyer & Engineer Questions Answered
What is ThermaX PSU?
ThermaX PSU is 3DXTech’s polysulfone filament — an amorphous aromatic sulfone polymer with a 190°C Tg, inherent UL 94 V-0 flame resistance, and excellent hydrolytic stability. It is a cost-effective alternative to ULTEM 9085 for applications requiring high-temperature performance without PAEK-class pricing.
What temperatures does ThermaX PSU require?
Extruder: 350–380°C with an all-metal hotend. Bed: 140–160°C on PEI or garolite. Heated chamber (≥70°C) is strongly recommended. Dry at 120°C for 4 hours before printing.
What is the difference between PSU, PPSU, and PES?
PSU (Polysulfone, 190°C Tg) is the most economical of the three. PPSU (Polyphenylsulfone, 220°C Tg) offers higher Tg and significantly better impact toughness. PES (Polyethersulfone, 220°C Tg) offers better high-temperature chemical resistance than PSU. Choose PSU for cost-sensitive applications; PPSU for maximum toughness; PES for superior chemical or solvent resistance at high temperature.
How does ThermaX PSU compare to ULTEM 9085?
PSU offers a slightly higher Tg (190°C vs 186°C) than ULTEM 9085, with comparable flame resistance (UL 94 V-0), better hydrolytic stability, and excellent ESCR. PSU typically prices below ULTEM 9085 at comparable spool sizes, making it the performance-per-dollar choice when FAA-specific FST certification is not required.
Is PSU autoclavable?
Yes. Polysulfone has good hydrolytic stability and can withstand steam autoclave cycles at 121–134°C. It is widely used in medical device housings and sterilization trays. However, PPSU offers better resistance to repeated autoclave cycles over time; for high-cycle medical applications, PPSU is the preferred choice.
Why is PSU available in both Natural and Black?
Natural PSU has an amber-translucent appearance while Black adds UV opacity and aesthetics for consumer-facing or UV-exposed components. Both colors use the same polysulfone base formulation — no flame-retardant additives — so properties are identical between colors.
Does PSU require a hardened steel nozzle?
No. ThermaX PSU is unfilled, so abrasion is not a concern. However, an all-metal nozzle rated for 400°C+ is recommended for sustained operation. Standard brass nozzles may soften at extended 380°C operation — stainless or hardened steel is an inexpensive upgrade.
Should I choose PSU or ThermaX PEEK?
Choose PSU for cost-sensitive applications requiring high-temperature flame resistance and good chemical/hydrolytic stability, or when a ULTEM 9085 alternative is needed at lower cost. Choose PEEK for maximum mechanical stiffness, higher tensile modulus, and the established biocompatibility profile for implant-adjacent applications. PEEK also prints at a higher temperature (375–410°C) and requires a hardened steel nozzle.