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-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

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

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.

A proof-of-concept composite component with electrical paths (black) 3D printed with standard PEEK body.

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.

A diode connected to a power source via an electrically conductive 3D printed path embedded in a PEEK model.

ESA's electrically conductive PEEK

Researchers at the European Space Research and Technology Centre (ESTEC) developed a unique blend of electrically conductive PEEK. This material printed in LPD Plus dual extrusion with a standard PEEK filament enabled printing composite models with advanced data and energy transfer features. All without loosing any of the PEEK's excellent thermal and mechanical properties.

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

Results and milestones

Using the Endureal's dual extrusion technology, we have made the world's first data transfer device 3D printed entirely out of PEEK polymers. A data transfer of 9600 bit/s has been achieved between two computers connected with USB cables and USB-RS232 converters through a 3D printed model. We have also fabricated models with built-in electrically conductive paths.

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.

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.

Zortrax Endureal Shield

Sustained industrial 3D printing with a service program including scheduled inspections conducted by an authorized representative. Find out more about the program’s benefits in the PDF below.

Download PDF

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*** / 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-PEI 1010, Z-PEI 9085, Z-ULTRAT Plus, Z-SUPPORT High-Temp (breakaway), Z-SUPPORT ATP (soluble with Z-SUPPORT ATP Activator)
External materials
Printing profiles available for filaments based on 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.
***Since the release of macOS Big Sur, we’ve been developing Z-SUITE’s best possible operation on this system and all its future updates. The available version is fully functional, however minor bugs may occur.

Get your 3rd generation industrial 3D printer

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