Many manufacturers of laboratory technology, diagnostic devices and surgical robots use 3D printing to produce plastic components such as miniature gears, rotating valves and swivelling levers, helping to save time and costs. However, many conventional printing materials contain PFAS chemicals, which may face future restrictions in the EU due to potential risks to people and the environment.

As a result, manufacturers in sensitive sectors such as medical technology are seeking alternative 3D printing materials. Addressing this need, igus has launched iglidur i2000, a new 3D printing material that does not contain any of the 96 PFAS substances considered critical in concentrations above 0.1 per cent by weight.

iglidur i2000 is a liquid, light-sensitive synthetic resin cured layer by layer using UV light in SLA and DLP printers. It enables the production of components with smooth surfaces and high precision, delivering quality comparable to injection moulding. The material is designed for moving and friction-loaded components, including small drive and gearwheels as well as bearing bushes.

A defining feature of the material is its lubrication-free performance. Solid lubricants are integrated directly into the resin, allowing low-friction and hygienic dry operation without grease. Unlike previous igus materials that relied on PTFE from the PFAS group, iglidur i2000 uses a PTFE-free alternative. This allows users to print components without concerns around PFAS regulations.

The material also offers high mechanical and thermal resilience. With a flexural strength of 74 MPa and a Shore D hardness of 80, iglidur i2000 provides strong wear resistance. It supports continuous operating temperatures from –20°C to 100°C and can withstand short-term exposure of up to 140°C.

In laboratory testing, a stainless-steel specimen was moved across the resin surface at 0.5 m/s under a surface pressure of 1.4 MPa. The wear rate was reduced from 63.97 µ/km with a standard resin to 0.52 µ/km, representing a 122-fold improvement. These results demonstrate the durability and abrasion resistance of the PTFE-free iglidur i2000 under high mechanical loads.