The real future of production lines

3rd generation industrial 3D printer
For high-tech manufacturing

Advanced thermal management enabling efficient work with high-performance polymers is what third generation 3D printers are all about, according to the industry’s thought leaders. Temperature of filaments in Zortrax Endureal LPD Plus 3D printer is tightly controlled at each stage of processing to achieve utmost precision and best possible mechanical properties of 3D printed parts.

High-temperature extruder

An advanced extruder can work at sustained temperatures as high as 480° C to support processing demanding filaments.

Heated printing chamber

Temperature in the printing chamber can reach up to 200° C to ensure best thermal conditions for high-temperature materials.

Heated build-platform

A build-platform supporting temperatures of up to 220° C to ensure appropriate stability to models.

Automated annealing

Endureal has an automatic annealing function that can be carried out after printing in order to achieve the highest mechanical properties of high-temperature materials.

Advanced thermal shielding

Thermally shielded extruder's compartment is always kept at low temperatures to ensure uninterrupted filament transmission.

Heated filaments' compartment

Filaments are stored in a secure, closed environment at temperature optimal for both high performance and standard polymers the Endureal is designed to work with.

Maintenance facilitated

Key components in the Zortrax Endureal have been designed to be easily maintained and fixed on the spot without voiding the warranty with the use of tools and parts provided in the Maintenance Kit.

Industrial safety systems

Zortrax Endureal has over 30 built-in sensors working in real-time to guarantee seamless operation in high-tech manufacturing and product development projects.

Blackout Response System

When a power outage is detected, Endureal uses the energy stored in built-in capacitors to save the exact position of the printing head. This way printing can be resumed from the same spot when the power is back on.

Monitored printing progress

Printing progress can be monitored remotely with a heat-resistant camera installed in the Endureal's printing chamber. The camera is capable of live video streaming and designed to work in demanding conditions.

Advanced filament sensors

Separate sensors work at all times to detect events when filament is jammed or depleted. The printer also monitors the weight of the filament spools to determine if there is enough material to complete the printing process.

Controlled filament's compartment

Filaments’ compartment creates an optimal environment for storing material spools. It is equipped with a moisture absorber which is responsible for reducing humidity to levels appropriate for highly hygroscopic materials.

Performance under control

A wide array of sensors ensure that the Zortrax Endureal always delivers best possible performance.

Temperature sensors constantly measure temperature of crucial components to prevent overheating.
Capacitive sensors measure build platform and nozzles' relative position to ensure calibration is on point.
Optical sensors working with no mechanical parts ensure precise extruder's positioning in all axes.
Fan stop sensors immediately detect when fans are disconnected or malfunctioning to ensure adequate cooling.
Extruder sensors detect a disconnection or failure in the extruder to ensure seamless operation.

Industrial build-volume

Build volume measuring 400 x 300 x 300 mm is large enough to accommodate full-sized structural industrial components. Due to soluble support printing capability, most of the build volume can be used by stacking models in batches arranged on top of the other.

Height (Z)
Width (X)
Depth (Y)
300 mm
400 mm
300 mm
11.8 in
15.7 in
11.8 in

Z-PEEK space-grade outgassing-compliant filament

Z-PEEK is one of the strongest polymers on the planet. It has strength-to-weight ratio comparable to stainless steel and thermal properties suitable for exposure to low Earth orbit environment. Z-PEEK meets ESA's outgassing requirements specified in the ECSS-Q-ST-70-02C standard.

CT scan of a 3D printed demonstrator made with Z-PEEK and ESA's conductive PEEK on Zortrax Endureal taken after thermal vacuum cycling test. The model showed no sings of degradation or decreased performance.

Excellent thermal properties

PEEK can withstand thermal-cycling in vacuum chambers used for space-qualification tests. PEEK samples have been exposed to 500 cycles of heating up to 130 °C and cooling down to - 70 °C with no adverse effects on their mechanical or chemical properties. PEEK parts are also confirmed to consistently withstand over 10 cycles of cooling down to cryogenic temperatures as low as - 196 °C.

Aerospace

Automotive

Chemical processing

Mechanical engineering

An element of bearing highly resistant to wear and abrasion.

High wear resistance

PEEK's wear resistance has been confirmed to be sufficient for PEEK/stainless steel gear pairs working at 1600 rpm for over 22 million cycles under 1 Nm load. PEEK is also strong enough for PEEK/metal sliding systems operating in both atmospheric and vacuum conditions. High wear resistance leads to limited debris accumulation in PEEK medical devices like joint replacement implants.

Aerospace

Automotive

Mechanical engineering

A bracket designed for a CubeSat, highly resistant to radiation.

High radiation resistance

In the MPAC & SEED experiment on the International Space Station, PEEK samples withstood 46 months of exposure to Low Earth Orbit environment. Prior to launch, samples passed multiple irradiation ground tests including atomic oxygen bombardment and UV exposure. PEEK is also resistant to gamma rays.

Space

A lightweight element of a deployable parabolic Ka-band antenna.

Great strength-to-weight ratio

Z-PEEK parts 3D printed on the Zortrax Endureal 3D printer were tested at ESA's ESTEC facilities in Netherlands and found to be among the strongest ever reported in scientific literature. Flexural strength at yield measured at 146 MPa and flexural modulus standing at 3500 MPa are values previously achievable only with injection molding.

Aerospace

Automotive

Mechanical engineering

A composite printing demonstrator made on Zortrax Endureal with Z-PEEK and conductive blend of PEEK supplied by ESA integrated on the WISA CubeSat PCB.

Outgassing compliant

Materials meant for space applications like Z-PEEK must pass rigorous outgassing tests before they are cleared for flight. Outgassing is a process of releasing gases accumulated in a solid in high vacuum. In space, such gases can condense on electronics or sensors and severely impair their performance. Z-PEEK passed all necessary tests and complies with ESA's ECSS-Q-ST-70-02C outgassing standard

Space

Z-PEI 1010 robust thermally stable industrial material

Z-PEI 1010 belongs to the same family of polyetherimides as Z-PEI 9085, but with higher rigidity, higher Heat Deflection Temperature, and broader chemical resistance. This filament is aimed at chemical industry, automotive, and mass manufacturing scenarios.

Rigid and durable air compressor cover 3D printed with Z-PEI 1010 on the Zortrax Endureal 3D printer.

High-rigidity

Z-PEI 1010 has higher rigidity than Z-PEI 9085 which means it would break rather than give in under critical loads. This makes it a good match for casings, covers, housings and industrial positioning jigs.

Automotive

Mass-manufacturing

Functional engine throttle housing 3D printed with Z-PEI 1010 on the Zortrax Endureal 3D printer.

High temperatures

The HDT (Heat Deflection Temperature) of Z-PEI 1010 stands at 208° C which is one of the highest values among all high-performance polymers. Components 3D printed with Z-PEI 1010 retain their properties and dimensional stability in a wide range of temperatures.

Automotive

Chemical processing

Engine coolant thermostat housing 3D printed with Z-PEI 1010 on the Zortrax Endureal 3D printer.

Chemical resistance

Z-PEI 1010 offers broad chemical resistance. The material does not react with automotive fluids, aqueous solutions, or halogenated hydrocarbons. It is therefore suitable for piping in chemical industry, heating and cooling systems, or metal-cleaning equipment.

Mechanical engineering

Chemical processing

Z-PEI 9085 flame-retardant aerospace-grade polymer

Based on a durable polyetherimide blend, Z-PEI 9085 has strength-to-weight ratio comparable to aluminum 6061 with much better thermal shock resistance. The material is designed primarily for aerospace and automotive engineering applications.

Flame-retardant cockpit panels for an airliner.

High flame-retardancy

Z-PEI 9085 has a UL94 V-0 flammability rating and has been tested in accordance with the FAR 25.853 procedures which means it can be safely used in aerospace interiors. This flammability rating means that a vertically oriented sample printed with Z-PEI 9085 extinguishes within 10 seconds from when the fire has been applied to it.

Aerospace

Automotive

Load-bearing components printed with Z-PEI 9085 exhibit properties comparable to their counterparts made with aluminum.

Flight-readiness

Z-PEI 9085 is strong enough for structural components in satellites. An 8U CubeSat 3D printed with this blend of polyetherimide has successfully passed pre-launch tests offering 46.77% weight penalty reduction compared to the same structure CNC'ed out of aluminum.

Aerospace

Automotive

Mechanical engineering

A turbo air intake manifold designed to work in contact with an engine block heating up to 120° C.

Excellent thermals

Z-PEI 9085 retains its mechanical properties in temperatures reaching 167° C which means its performance is on par with aerospace-grade aluminum 6061. That's why Z-PEI can be used for various parts in automobile engines which typically have operating temperatures between 90° C and 105° C.

Automotive

Aerospace

Chemical processing

Components 3D printed with Z-PEI 9085 do not release toxic fumes when exposed to fire or high temperatures.

Proven outgassing properties

Z-PEI 9085 is made out of a proven blend of polyetherimide which has passed rigorous outgassing tests performed by both NASA and ESA. It is one of the few 3D printing materials cleared for use onboard the International Space Station.

Aerospace

Chemical processing

Cutting Edge Research Platform

We are constantly working to further expand Zortrax Endureal's capabilities. This 3D printer is used in numerous joint research projects like the one we do with the support of the European Space Agency.

An experimental composite PEEK model used for the world's first data transfer routed through a device 3D printed entirely out of PEEK polymers.

Reinventing dual extrusion

Dual extrusion LPD Plus technology has been traditionally used to print support structures out of a dedicated support material different from the one used for the model. But we wanted to take it one step further and build a capability to use the Endureal's LPD Plus technology for printing composite components out of two blends of PEEK in one go. For space applications, we 3D printed such composite models with standard Z-PEEK and ESA-developed electrically conductive blend of PEEK.

Michał Siemaszko, Head of Research and Development at Zortrax, at the IEEE Aerospace conference in the USA, where he presented the results of the research project that Zortrax conducted with ESA.

First research paper co-authored with ESA

After nearly two years of research, Zortrax engineers published the first research paper co-authored with ESA's team led by dr Ugo Lafont, an expert on space-grade polymeric materials. Composite models 3D printed on the Zortrax Endureal passed tests in thermal vacuum chambers and their mechanical properties were found to be among the highest ever reported in scientific literature. The paper passed peer-review process and was presented at the IEEE Aerospace Conference in Big Sky, Montana, USA.

One of the first Z-PEEK samples 3D printed on the Zortrax Endureal successfully covered with metallic coating.

Covering Z-PEEK parts with metals

Developing a technology to apply metallic coatings and reinforcing structures to parts 3D printed with Z-PEEK on the Zortrax Endureal is the aim of the research project realized by Zortrax under ESA contract with Astronika, a company specializing in space mechanisms, and Crido R&D, who are responsible for electroplating solutions. Z-PEEK parts covered with various metals are expected to provide high-quality, lightweight alternative to pure metals alloys.

Industrial dual-extrusion

The Endureal has an advanced dual-extrusion system capable of printing high-temperature filaments with a specially dedicated support material. The extruder components and cables are thermally shielded from the main chamber with an elastic, nanoporous insulator to achieve the lowest possible thermal conductivity. Designed for processing challenging materials, the Endureal can also work with a wide range of cost-effective filaments like Z-ULTRAT Plus. The printer supports both single- and dual-extrusion modes.

Dual extrusion
Single extrusion

Heated aluminum build-platform

The Endureal is equipped with an aluminum build platform covered with a PEI plate to ensure proper adhesion of high-performance polymers. The platform can be heated up to 220° C.

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Integrated prototyping

Wide range of materials supported by Zortrax Endureal makes it possible to go from early low-cost prototypes to the final high-performing part using one manufacturing device.

Modular manufacturing architecture

Zortrax products, the Endureal included, can work together in highly scalable, modular systems. While the Endureal's main purpose is printing critical components out of very advanced materials, the early prototyping tasks can be easily ceded to clusters of low-maintenance desktop 3D printers like the M Series Plus or M300 Dual.

Cloud-based management

All network-enabled Zortrax 3D printers along with the staff responsible for running them can be remotely managed with Zortrax inCloud 3D printing management service. Professional and Enterprise inCloud subscription plans enable organizing people into teams with assigned 3D printers. Data on how human and 3D printing resources have been employed is aggregated in neatly spaced panels.

Workflow in industrial manufacturing

Step 1: Initial design

A high-performing part is designed in CAD software.

Step 2: Concept models

Concept models are printed with low-cost materials.

Step 4: Post-processing

Post-processing techniques like annealing are applied to achieve target properties of the material.

Step 3: Preliminary evaluation

Concept models are used for preliminary evaluation.

Step 1: Initial design

A high-performing part is designed in CAD software.

Step 2: Concept models

Concept models are printed with low-cost materials.

Step 3: Preliminary evaluation

Concept models are used for preliminary evaluation.

Step 4: Post-processing

Post-processing techniques like annealing are applied to achieve target properties of the material.

Unlimited scalability

Zortrax industrial systems are designed in such a way that new devices can be added at all times without incurring additional integration costs. It is possible to quickly install more clusters of cost-efficient M Series machines when an organization needs to increase production volume, more Endureal 3D printers for high-tech applications, or more Apoller devices to expand post-processing capabilities.

Cost-free flexibility

A Zortrax industrial system comprising of the Endureal 3D printer supported by a cluster of M Series machines and the Apoller post-processing devices leaves plenty of room for cost-free, on-the-fly adjustments. Even projects that have reached the stage where final parts are printed out of target materials on Endureal 3D printers can be quickly reversed to initial prototyping on M Series machines with a few clicks in Zortrax inCloud.

Easy to implement
and run

Being a full-fledged industrial machine, Endureal can be implemented as easily as Zortrax desktop-class 3D devices. Intuitive user interface and software with carefully tuned settings predefined for each dedicated filament make Endureal ready to work at full capacity from day one. The ease of implementation extends further into running the printer due to business continuity kit containing everything necessary for fast and efficient in-house maintenance.

Specification for Zortrax Endureal

Device

Build volume
400 x 300 x 300 mm (15.7 x 11.8 x 11.8 in)*
Nozzle diameter
0.4 mm (0.016 in)
Extruder
Dual material
Extruder cooling system
Two fans cooling the extruder, radial fan cooling the print
Hotend
High-temperature dual hotend**
Platform
Heated; aluminum plate coated with PEI
Material sensors
2 x mechanical endstop, 2 x material weight sensor
Connectivity
Wi-Fi, Ethernet, USB
Operating system
Android
Processor
Quad Core
Touchscreen
7" IPS 1024 x 600
Camera
Yes

Electrical

AC Input
120 V ~ 13 A 50/60 Hz
200 - 240 V ~ 9.5 A 50/60 Hz
Maximum power consumption
120 V - 1600 W
200-240 V - 2300 W

Software

Software bundle
Z-SUITE
Supported input file types
.stl, .obj, .dxf, .3mf, .ply
Supported operating system
Mac OS Mojave and newer versions / Windows 7 and newer versions

In the box

3D printer, Z-SUITE, Starter Kit, Maintenance Kit, spool of model material, spool of support material, spool of high-temperature model material, spool of high-temperature support material, USB memory stick.
Maintenance Kit contents: material endstop (2 pcs.), extruder filament gear (2 pcs.), extruder, filters set (carbon & HEPA) (2 pcs.), PEI plate (2 pcs.), high-temperature hotend module (2 pcs.), extruder cable.

Printing

Technology
LPD Plus (Layer Plastic Deposition Plus) advanced technology depositing melted thermoplastics with break-away and dissolvable support structures
Layer resolution
200-250 microns (for 0.4 mm nozzle)
Minimal wall thickness
450 microns (for 0.4 mm nozzle)
Platform levelling
Automatic measurement of platform points' height

Temperature

Maximum printing temperature (extruder)
480 °C (896 °F)
Maximum platform temperature
220 °C (428 °F)
Maximum build chamber temperature
200 °C (392 °F)
Ambient operation temperature
17-30 °C (63 - 86 °F)
Storage temperature
0-35 °C (32 - 95 °F)

Filaments

Dedicated for single extrusion
Z-PEI 9085, Z-ULTRAT Plus
Dedicated for dual extrusion
Z-PEEK, Z-PEI 1010, Z-PEI 9085, Z-ULTRAT Plus, Z-SUPPORT High-Temp (breakaway), Z-SUPPORT ATP (soluble with Z-SUPPORT ATP Activator), Z-SUPPORT ATP 130 (soluble with Z-SUPPORT ATP Activator)
External materials
Printing profiles available for filaments based on PEEK, PEI 9085, PEI 1010 and ABS
Support
Mechanically removed - printed with the same material as the model;
Breakaway - printed with a different material than the model;
Soluble - printed with a different material than the model
Filament container
Spool
Filament diameter
1.75 mm (0.069 in)
*In dual-extrusion mode project's dimensions cannot exceed 390 mm (15.35 in) in the X axis and/or 290 mm in the Y axis.
**Remember to use a separate high-temperature hotend module with each high-temperature material type you use.

Get your 3rd generation industrial 3D printer

3D print with the strongest polymers on the planet. Request a quote for Zortrax Endureal.