Micah Chaban is the Founder and Vice President of Sales at RapidMade, a company at the forefront of advanced manufacturing solutions. With a deep background in engineering and business development, Micah has been instrumental in driving innovation in additive manufacturing, thermoforming, and machining. RapidMade specializes in producing high-performance components, particularly those requiring flame-retardant materials, for industries such as aerospace, medical, electronics, and industrial equipment.
Flame-retardant resins are crucial in many industries. What challenges do companies face when selecting and manufacturing with these materials?
Micah Chaban: One of the biggest challenges is material selection. Not all flame-retardant resins perform the same across different manufacturing methods. For instance, a material that excels in thermoforming may not be suitable for 3D printing or machining due to differences in mechanical properties, thermal stability, and process compatibility. Companies also need to ensure compliance with UL 94 V-0 standards, which can be complex depending on the application. Our role at RapidMade is to guide customers through these choices, ensuring they get the right balance of fire resistance, durability, and cost-effectiveness.
How does RapidMade approach manufacturing flame-retardant components across different processes like 3D printing, thermoforming, and machining?
Micah Chaban: Each manufacturing method offers unique advantages. With 3D printing, we can create highly customized and intricate designs, which is especially useful for aerospace and electronics applications. Thermoforming is ideal for producing large, lightweight panels and enclosures with cost efficiency. Machining, on the other hand, provides unmatched precision and strength for critical components. At RapidMade, we evaluate the application’s requirements—whether it’s mechanical performance, heat resistance, or scalability—and recommend the best process accordingly.
Are there specific flame-retardant materials that stand out in 3D printing?
Micah Chaban: Absolutely. ULTEM™ 9085 is a standout for FDM 3D printing, particularly in aerospace. It has an excellent strength-to-weight ratio and meets stringent flame, smoke, and toxicity (FST) standards. For SLA/DLP printing, xPro 9400 B FR is an excellent choice because of its high heat resistance and smooth finish, making it great for electronic enclosures and industrial components.
When should a company choose thermoforming over 3D printing or machining for flame-retardant parts?
Micah Chaban: Thermoforming is the best option when you need large, thin-walled components at scale. If you’re manufacturing interior panels for transportation, medical equipment enclosures, or protective covers, thermoforming provides a cost-effective way to achieve durability and flame resistance. Materials like Kydex and Boltaron are commonly used because they combine impact resistance with strong flame-retardant properties.
How does machining compare when working with flame-retardant plastics?
Micah Chaban: Machining is the go-to method for high-strength, precision parts. Unlike additive manufacturing or thermoforming, machining starts with a solid block of material, allowing for tight tolerances and superior structural integrity. Flame-retardant polycarbonate, acetal, and PVDF are among the most commonly machined plastics because they maintain their mechanical properties while meeting UL 94 V-0 requirements. This is particularly important for industrial applications that demand extreme durability and chemical resistance.
What trends do you see shaping the future of flame-retardant materials and manufacturing?
Micah Chaban: We’re seeing increasing demand for lightweight, high-performance materials that meet fire safety regulations without compromising mechanical strength. Sustainability is another major trend—companies are looking for recyclable flame-retardant plastics that reduce environmental impact. Additionally, advancements in 3D printing are expanding the range of flame-resistant materials that can be used in additive manufacturing, allowing for more complex and efficient designs.
How can companies work with RapidMade to develop their flame-retardant components?
Micah Chaban: We make the process straightforward. Whether you’re in the early design phase or need full-scale production, we provide material selection guidance, prototyping, and manufacturing support across 3D printing, thermoforming, and machining. Our goal is to help companies navigate the technical and regulatory challenges of flame-retardant materials while delivering high-quality, cost-effective solutions.
For more information, visit RapidMade.com or contact us at [email protected]. Whether you need custom flame-retardant parts or guidance on the best manufacturing approach, our team is ready to help.
