Introduction
Micah Chaban has spent over 15 years in manufacturing, witnessing firsthand how additive manufacturing has evolved from a niche technology to a legitimate production tool. As the Founder and VP of Sales and Marketing at RapidMade, he’s at the forefront of helping companies integrate high-performance EnvisionTEC resins 3d print into their manufacturing processes. We sat down with Micah to talk about how these materials compare to traditional thermoplastics, where engineers can use them, and what the future holds for 3D printing in industrial applications.
Why are EnvisionTEC resins such a big deal for industrial manufacturing?
Micah Chaban: If you had told me 10 years ago that DLP resins could replace injection-molded ABS, polypropylene, or even high-performance thermoplastics like PEEK, I wouldn’t have believed you. But we’re there now.
What makes EnvisionTEC resins a game-changer is their mechanical properties. They aren’t just for prototyping anymore. These materials have high tensile strength, impact resistance, heat deflection, and even flame retardancy—which means you can use them for actual end-use parts, aerospace components, and even production tooling.
For a long time, the biggest limitation of 3D printing was material performance. Sure, you could print parts quickly, but they weren’t strong enough, or they degraded under heat and stress. EnvisionTEC has cracked that problem. Their hard plastics, high-temperature resins, elastomers, and castable materials are giving engineers real alternatives to traditional manufacturing.
How do EnvisionTEC hard plastic resins compare to traditional materials like ABS and polycarbonate?
Micah Chaban: They’re shockingly close. I mean, we’ve been working with EnvisionTEC’s Loctite E-3843 and E-RigidForm, and these resins behave a lot like injection-molded ABS or polycarbonate, but with the added benefits of better surface quality and geometric flexibility.
Take E-RigidForm, for example. It has a tensile strength of 73 MPa and a high modulus, which puts it right in line with polyurethane-based thermoplastics. That’s what you want if you’re making rigid enclosures, housings, or parts that need to withstand stress.
Then there’s Loctite E-3843, which is an ABS alternative. It’s impact-resistant, has a tensile strength of 60 MPa, and is great for load-bearing applications like brackets, fixtures, and even consumer electronics casings.
I think a lot of engineers would be pleasantly surprised by how well these materials perform. You’re not sacrificing strength to get the benefits of 3D printing.
What about high-temperature resins? Can they really replace aerospace-grade thermoplastics?
Micah Chaban: This is where things really get interesting. High-temperature EnvisionTEC resins like Loctite 3955 and E-Perform are pushing the boundaries of what’s possible with DLP printing.
Let’s take Loctite 3955. It’s an aerospace-grade polymer that meets UL94 V-0 and Airbus flame resistance standards. That means it can be used for interior aircraft components, railcar parts, and other applications where flame retardancy is a requirement. And it’s not just about heat resistance—it has a heat deflection temperature (HDT) of 300°C while maintaining strong mechanical integrity.
Then you’ve got E-Perform, which is a ceramic-filled PEEK alternative. It’s ideal for wind tunnel components, industrial tools, and aerospace fixtures that need high stiffness and extreme heat resistance.
If you’re working on aviation, defense, or high-heat industrial applications, these materials are legitimate replacements for injection-molded high-temperature thermoplastics. That’s a big deal.
Elastomeric resins have been tough to get right in 3D printing. Has EnvisionTEC solved that?
Micah Chaban: Elastomers have been tricky for 3D printing because you need the right balance of flexibility, durability, and tear strength. A lot of printed elastomers end up being too brittle or too soft to really hold up in industrial environments.
But EnvisionTEC’s Elastic ToughRubber™ series is the real deal. You’re getting materials that behave like Shore A 70 or Shore A 90 rubber, but with the advantages of 3D printing.
For example, Elastic ToughRubber™ 70 has a tear strength of 31 kN/m and an elongation of 400%, which makes it a great alternative to traditional TPU or silicone for wearables, seals, and shock absorbers.
Then you’ve got Elastic ToughRubber™ 90, which is more rigid but still flexible. It’s great for automotive bushings, industrial seals, and soft-touch components.
If you’re in automotive, medical devices, or industrial manufacturing, these materials open up a lot of new possibilities. You can print custom-fit gaskets, flexible enclosures, or high-impact parts with no tooling costs.
How do castable resins compare to traditional investment casting methods?
Micah Chaban: Castable resins are where 3D printing really shines. Traditional investment casting is time-consuming and labor-intensive—you have to carve a wax pattern, create a mold, and then go through multiple steps to produce a final part.
With EnvisionTEC’s castable resins like EasyCast 2.0 and WIC100 Series, you can print high-resolution, high-detail patterns directly from a CAD file. These materials burn out cleanly, leaving behind a perfect mold for metal casting.
We’ve worked with jewelry designers, aerospace manufacturers, and even medical companies who are using these materials to cut lead times in half. You get finer details, faster turnaround, and way more design flexibility than traditional casting allows.
So where do you see the future of 3D printing in industrial manufacturing?
Micah Chaban: We’re at a turning point. 3D printing isn’t just for prototyping anymore—it’s a real production tool. With materials like EnvisionTEC’s resins, engineers can now print parts that rival injection-molded and machined components in terms of strength, durability, and heat resistance.
I think we’re going to see more aerospace and automotive manufacturers integrating 3D printing into their production lines. It won’t replace traditional manufacturing completely, but for low-volume, high-performance, and custom applications, DLP printing will be the smarter, faster, and more cost-effective option.
And honestly, the biggest shift is going to come from engineers themselves. Once they realize they can design and produce parts in days instead of weeks—without the constraints of traditional tooling—it’s going to change how products are developed.
Find the Right Material for Your Next Project
If you’re looking to integrate high-performance EnvisionTEC resins into your manufacturing workflow, RapidMade can help. Whether you need hard plastics, heat-resistant polymers, elastomers, or castable resins, we can guide you to the right solution for your application.
Visit RapidMade today to learn more about how we can help you make the most of advanced 3D printing materials.
