Design for Additive Manufacturing

As a full-service engineering and design firm, we offer concept development through prototyping, first article, and small batch production. We are experts in determining applications, materials, and processes for delivering quality rapid prototypes and end-use parts.

We can optimize your design for Carbon printers by minimizing support material, reducing hand finishing time, developing custom surface textures, and applying lattice structures.

Harness our team’s expertise to take advantage of digital printing technology for end-use-quality prototypes and bridge runs of 100–10,000 parts.

Benefits of 3D Printing with Carbon

The Carbon DLS™ printing process is enabled by a thin, oxygen-permeable window and dual-cure materials. The use of dual-cure materials with a second heat-activated chemistry ensures that printed parts overcome the weaknesses and brittleness commonly associated with traditional resin-based 3D printing. This results in robust mechanical properties comparable to traditional manufacturing plastics, including injection molded parts.

Here’s how it works:


The resolution and gentleness of the Carbon process provides the ability to work with a wide range of materials, meeting the surface finish and detail requirements necessary for end-use parts. Furthermore, Carbon offers a range of materials that are comparable to traditional thermoplastics commonly used in manufacturing.

Here is a complete list of Carbon materials with their thermoplastics with equivalent mechanical properties.

Carbon Design Partner

As the first Carbon Global Design Partner, we have been at the forefront leveraging digital tools for design for additive manufacturing (DfAM).  We can assist with identifying applications, material selection, process development, and much more. Merging our design experience and on-site manufacturing helps us accelerate the product development process.

Partnering with Sherpa

At Sherpa, our focus is on high quality parts, delivered in a timely fashion.

We can take your design files and print them directly or suggest modifications to improve the outcome from the printing process. We do not believe in the “upload files and pray” approach. You will always have an additive manufacturing specialist on your project from initial review to final delivery.

Select Work Examples

Take a look at two of many projects we elevated with Carbon 3D printing technology:

Power Supply Air Ducts

Reimagining a power supply air duct for production with Carbon DLS technology cut the concept design’s cost in half and optimized performance under higher ambient temperatures.

Learn more
3d printing in shoe manufacturing

Designing a custom composite cycling shoe Sherpa Design presents an innovative process to make a custom composite cycling shoe utilizing 3D printing. This white paper offers an exclusive glimpse into…

Learn more
See more of our work

Our Machines:

  • Carbon M2
  • Carbon M3 Max
  • Carbon Smart Part Washer

Carbon 3D Printing Materials

CE  221– CYANITE ESTER

CE 221 is a high-performance resin with excellent strength, stiffness, and temperature resistance.

  • Ultimate Tensile Strength:
    85 MPa | 12 ksi
  • Elongation at Break:
    3%
  • Tensile Modulus:
    3900 MPa | 566 ksi
  • Impact Strength (Notched):
    15 J/m | 0.28 ft-lb/in
  • Heat Deflection Temperature:
    230° C | 446° F
  • Comparable Thermoplastics:
    High-Performance (PEEK, PEI, PSU, PSSU)

EPU 40 – ELASTOMERIC POLYURETHANE

A high-performance polyurethane elastomer, EPU 40 is a good choice for applications that require high elasticity, resilience, and tear resistance.

  • Durometer (Shore A Hardness):
    68
  • Elongation at Break:
    300%
  • Bayshore Resilience:
    17%
  • Glass Transition Temperature:
    10 °C  | 50 °F
  • Tear Strength:
    20 kN/m  | 114.2 lbf/in
  • Comparable Thermoplastics:
    Thermoplastic Polyurethane Elastomers (TPU)

EPX 82 – EPOXY

EPX 82 is a high-strength engineering material with excellent long-term durability and mechanical properties comparable to lightly glass-filled thermoplastics. Its functional toughness lends itself well to a variety of automotive and industrial applications.

  • Ultimate Tensile Strength:
    84 MPa | 12 ksi
  • Elongation at Break:
    8%
  • Tensile Modulus:
    2800 MPa | 406 ksi
  • Impact Strength (Notched):
    45 J/m | 0.84 ft-lb/in
  • Heat Deflection Temperature:
    130 °C  | 266 °F
  • Comparable Thermoplastics:
    High-Performance (PEEK, PEI, PSU, PSSU), PBT, Polyamides / Nylons, Polycarbonate, Polypropylene

FPU 50 – FLEXIBLE POLYURETHANE

FPU 50 is an impact-, abrasion-, and fatigue-resistant semi-rigid material. Its qualities makes it a solid choice for parts that must withstand repetitive stresses.   

  • Ultimate Tensile Strength:
    25 MPa | 4 ksi
  • Elongation at Break:
    200%
  • Tensile Modulus:
    700 MPa | 102 ksi
  • Impact Strength (Notched):
    40 J/m | 0.75 ft-lb/in
  • Heat Deflection Temperature:
    70° C | 158° F
  • Comparable Thermoplastics:
    Polypropylene

RPU 70 – RIGID POLYURETHANE

A tough, moderately heat-resistant material, RPU 70 is excellent for parts requiring a high level of strength.

  • Ultimate Tensile Strength:
    40 MPa | 6 ksi
  • Elongation at Break:
    100.0%
  • Tensile Modulus:
    1700 MPa | 247 ksi
  • Impact Strength (Notched):
    25 J/m | 0.28 ft-lb/in
  • Heat Deflection Temperature:
    60° C | 140°F
  • Comparable Materials:
    ABS, PMMA / Acrylic, POM

SIL 30 – SILICONE URETHANE ELASTOMER

SIL 30 is a soft, biocompatible, and tear resistant silicone urethane elastomer, ideal for comfortable skin-contact applications.

  • Durometer (Shore A Hardness):
    35
  • Elongation at Break:
    350%
  • Bayshore Resilience:
    20%
  • Glass Transition Temperature:
    10° C | 50°F
  • Tear Strength:
    10 kN/m  | 57.1 lbf/in
  • Comparable Thermoplastics:
    SEBS TPE

UMA 90 – URETHANE METHACRYLATE

UMA 90 is a single-cure resin with enhanced toughness, appropriate for use in prototypes as well as manufacturing jigs and fixtures.

  • Ultimate Tensile Strength:
    30 MPa | 4 ksi
  • Elongation at Break:
    30%
  • Tensile Modulus:
    1400 MPa | 203 ksi
  • Impact Strength (Notched):
    33 J/m | 0.56 ft-lb/in
  • Heat Deflection Temperature:
    45° C | 113°F
  • Comparable Materials:
    ABS, POM

LOCTITE® IND405 (clear)

Henkel LOCTITE® 3D IND405 is a tough, semi-rigid material with an attractive frosted clear finish.

  • Ultimate Tensile Strength:
    42 MPa | 6 ksi
  • Elongation at Break:
    120%
  • Tensile Modulus:
    1500 MPa | 218 ksi
  • Impact Strength (Notched):
    50 J/m | 0.94 ft-lb/in
  • Heat Deflection Temperature:
    53° C | 127.4 °F
  • Comparable Materials:
    PMMA, Polycarbonate, Polypropylene, POM

EPX 86FR

EPX 86FR displays flame retardance, functional toughness, high strength, and long-term stability.

  • Ultimate Tensile Strength:
    94 MPa  | 14 ksi
  • Elongation at Break:
    5%
  • Tensile Modulus:
    3300 MPa | 479 ksi
  • Impact Strength (Notched):
    30 J/m  | 0.56 ft-lb/in
  • Heat Deflection Temperature:
    135 °C  | 275 °F
  • Comparable Materials:
    High-Performance (PEEK, PEI, PSU, PSSU), PBT, Polyamides / Nylons

RPU 130

RPU 130 is a strong and tough engineering polyurethane offering a unique combination of durability, impact resistance, and performance at elevated temperatures.

  • Ultimate Tensile Strength:
    35 MPa  | 5 ksi
  • Elongation at Break:
    100%
  • Tensile Modulus:
    900 MPa | 131 ksi
  • Impact Strength (Notched):
    75 J/m  | 1.41 ft-lb/in
  • Heat Deflection Temperature:
    120 °C  | 248 °F
  • Comparable Materials:
    ABS, High-Performance (PEEK, PEI, PSU, PSSU), Polyamides / Nylons, Polycarbonate, Polypropylene, POM

LOCTITE® 3843 (Matte Black)

Henkel Loctite® 3843 is a high-strength engineering plastic with good impact resistance and excellent surface finish. It is ideal for a wide variety of tooling applications on the production floor.

  • Ultimate Tensile Strength:
    51 MPa  | 7 ksi
  • Elongation at Break:
    43%
  • Tensile Modulus:
    1800 MPa | 261 ksi
  • Impact Strength (Notched):
    50 J/m  | 0.94 ft-lb/in
  • Heat Deflection Temperature:
    63 °C  | 145.4 °F
  • Comparable Materials:
    ABS, PMMA

LOCTITE® IND147 (Black)

Henkel Loctite IND147 Black, certified for Carbon printers, is a photopolymer resin with high stiffness and high temperature resistance.

  • Ultimate Tensile Strength:
    67 MPa  | 10 ksi
  • Elongation at Break:
    2.4%
  • Tensile Modulus:
    3190 MPa | 463 ksi
  • Impact Strength (Notched):
    14.6 J/m  | 0.27 ft-lb/in
  • Heat Deflection temperature:
    291 °C  | 555.8 °F
  • Comparable Materials:
    High-Performance (PEEK, PEI, PSU, PSSU)

Contact Us

Ready to embark on a transformative engineering journey? Our team of experts is eagerly waiting to guide you through the possibilities of Carbon 3D Printing and engineering design. Contact us today to discuss your unique requirements and let us help you bring your ideas to life.

Experience What’s Possible with a Carbon Sample Kit

The best way to get a sense of what’s possible with Carbon printed parts is to hold them in your hand. We’ve curated sample kits of flexible elastomers and rigid polymers.

Order now