BASF Ultracur: High-Performance Photopolymers for Advanced 3D Printing

Overview of BASF Ultracur3D® Photopolymers

The basf Ultracur portfolio, often referred to simply as ultracur, is a family of Ultracur3D® Photopolymers engineered for demanding additive manufacturing. Developed by basf Forward AM, these photopolymer products are designed to deliver short cure cycles, repeatable processing, and long-term stability. In practical terms, Ultracur materials help resin users move beyond simple prototypes toward functional components made from reliable performance materials. The range includes multiple product lines—Rigid Line, Tough Line, and Flexible/Elastomeric Line—so manufacturers can match properties to real-world applications and still achieve industry-leading accuracy on modern resin systems.

What makes ultracur different from conventional resins is its chemistry: BASF uses polyurethane know-how to create a robust photopolymer material platform with better mechanical retention and UV stability than standard acrylic blends. These high-performance resins are widely used with resin printers that support Stereolithography (SLA), Digital Light Processing (DLP), and LCD-based systems, making the portfolio one of the most flexible sets of industrial-grade printing materials available today.

Key Features of Reactive Urethane Photopolymers

Ultracur is built on Reactive Urethane Photopolymers, a class of polyurethane-based resins that offers strong toughness, low shrinkage, and stable curing. Unlike many commodity resin blends, this photopolymer material can reach high stiffness or high elasticity without fragile behavior. That is why ultracur is often selected for parts requiring excellent strength, abrasion resistance, and dimensional stability. The resins also maintain low water uptake and strong surface finish after post-curing, which supports long-life end-use applications.

Another advantage is predictable processing: these printing materials produced by BASF are tuned to minimize settling, reduce viscosity spikes, and keep printing consistent in long production runs. Even highly filled options like Ultracur3D® RG 3280 keep workable viscosity for industrial workflows, making them true high-performance resins rather than lab-only formulations.

Applications in Industrial and Functional 3D Printing

Because basf designed Ultracur for functional output, these photopolymer products serve high-performance applications across tooling, jigs and fixtures, housings, connectors, and short-run manufacturing. Rigid grades are used for precise structural parts, tough grades for impact-loaded components, and elastomeric grades for seals, gaskets, and soft-touch prototypes. In each case, the key goal is the same: stable printing, repeatable post-curing, and mechanical performance that holds up outside the printer.

Product Lines and Material Categories

To keep selection clear, BASF Forward AM divides Ultracur3D® Photopolymers into dedicated families. Each line focuses on a “property core,” but still shares a consistent process window so users can keep stable printer profiles when switching between different printing materials.

Rigid Line: High Strength and Dimensional Stability

The Rigid Line is engineered for stiffness, low shrinkage, and stable dimensions. Ultracur rigid grades are widely used when users need to achieve industry-leading accuracy and maintain tight tolerances after curing. Notable rigid materials include RG 35, RG 1100, and the ceramic-filled Ultracur3D® RG 3280. These rigid performance materials are ideal for high-precision prototypes, fixtures, housings, and tooling cores.

Tough Line: Impact-Resistant Multi-Purpose Resins

The Tough Line is the most versatile family in the portfolio. These tough multi-purpose resins are built for impact resistance and consistent elongation, bridging the gap between rigid engineering plastics and flexible polymers. BASF positions Tough Line grades as dependable multi-purpose materials for functional testing, prototyping, and end-use components with mechanical load. A leading example is ST 45, which provides excellent strength, high toughness, and smooth surfaces with fast exposure cycles. :

Flexible/Elastomeric Line: Elasticity and Softness for Dynamic Parts

The Flexible/Elastomeric Line includes Flexible Resin formulations and true elastomeric resins, designed for dynamic parts that bend, return, and withstand repeated deformation. BASF groups FL and EL products here, such as FL 300, EL 60, and EL 4000. These printing materials produced for elasticity are used for soft grips, gaskets, snap-fit interfaces, and flexible prototypes that still need predictable curing.

Dental Line: Precision Resins for Medical and Dental Use

The Ultracur dental family provides specialized Dental Resin options for accurate modeling and safe handling. BASF dental materials are formulated to achieve industry-leading accuracy in fit and surface finish, supporting orthodontic models, thermoforming bases, and lab workflows that depend on stable dimensional repeatability. Ultracur dental grades are also optimized for consistent washability and predictable light penetration in common dental printer setups.

Daylight Line: Resins for Large-Scale and Open-Source Printing

The Daylight family, including entries like EPD 1086 and EPD 2006, is designed for open-platform and large-format printers that use visible-light curing. These photopolymer products provide good toughness and stable detail at scale, making them cost-efficient printing materials for large prototypes, fixtures, and repeatable tooling in daylight systems.

SLA Line: Resins Optimized for Stereolithography

BASF also offers an SLA-focused family, including resins referenced as Ultracur3D® SLA 7700. These are tuned specifically for Stereolithography (SLA) platforms, with low shrinkage and high dimensional stability to support engineering output and precise molds. SLA grades keep stable viscosity and predictable cure depth, which supports consistent printing and post-processing.

Supplementary Line: Additives and Post-Processing Solutions

The supplementary family supplies workflow enhancers such as Ultracur Colour Kit and cleaners. These additions allow users to modify base resins for colored output and to remove uncured residue effectively. BASF positions these as supportive tools that improve handling, surface finishing, and the overall quality of printed parts across all Ultracur lines.

Featured Ultracur3D® Materials

The Ultracur portfolio includes multiple flagship resins that are widely used in industrial workflows. Below is a practical, application-driven look at key materials.

Ultracur3D® ST 45 / ST 80 / ST 1400 / ST 7500 : Tough Resin for Functional Prototypes

ST 45, also described as a Tough Resin, is one of the best-known Tough Line entries. It is a reactive urethane photopolymer designed for functional prototypes and end-use parts requiring excellent strength and long-term toughness. ST 45 prints fast with reliable surfaces and is frequently chosen for enclosures, brackets, clips, and durable mechanical models.

Ultracur3D® RG 3280 Phrozen BASF Protowhite Rigid White / : Ceramic-Filled Resin with Extreme Stiffness

Ultracur3D® RG 3280 is a premium Rigid Line resin filled with ceramic particles. Its high stiffness and temperature resistance make it suitable for tooling inserts, molds, wind-tunnel models, and structural parts where creep and deflection must be minimized. Despite high filler loading, RG 3280 keeps manageable viscosity and low settling, which supports stable production use.

Ultracur3D® RG 1100: High-Strength Resin for Structural Parts

RG 1100 is another Rigid Line flagship known for high stiffness, strong chemical resistance, low water uptake, and broad temperature stability. It is a go-to resin for structural prototypes, housings, and fixtures that need rigid performance under real conditions. In applications where users must achieve industry-leading accuracy and preserve mechanical properties after curing, RG 1100 is a reliable choice.

Ultracur3D® RG 35 / RG 50 : Rigid Resin with High Accuracy

RG 35 focuses on high detail, low shrinkage, and a smooth surface finish with very high stiffness. When users need to achieve industry-leading accuracy for parts like precision jigs, connectors, or mold masters, RG 35 delivers stable dimensional output and easy polishing. As a core Rigid Line resin, it supports strong print repeatability across batches.

Ultracur3D® FL 300: Flexible Resin for Elastic Applications

FL 300 is a Flexible Resin built for low hardness and strong elongation at break. It sits in the Flexible/Elastomeric Line and supports functional parts that must bend without tearing. Common uses include soft fixtures, flexible covers, ergonomic grips, and prototypes that simulate rubber-like compliance.

Ultracur3D® EL 60 / EL 150 and EL 4000 : Elastomeric Resins for Soft Components

EL 60 is a soft, elastic resin with rapid rebound and easy printability even on fine structures. It is ideal for seals, compliant clips, and soft-touch prototypes. EL 4000 offers higher hardness and tear resistance, targeting flexible parts that require strength and durability. Both are industrial-grade elastomeric resins in the Flexible/Elastomeric Line.

Ultracur3D® DM 2304 N: Dental Resin for Safe and Accurate Printing

DM 4505 N belongs to the dental family, formulated as a precise Dental Resin for dental models and safe clinical workflows. BASF dental grades are designed to print with high fidelity, stable fit, and detailed surface capture so labs can maintain consistent model production.

Post-Processing and Customization Tools

Post-processing is a critical stage for Ultracur because it directly affects final mechanical performance. BASF provides supportive tools to enhance surfaces and enable color control across multiple resin families.

Ultracur3D® Coat F+: Surface Enhancement Coating

Ultracur3D® Coat F+ is a flexible surface coating intended to upgrade elastic Ultracur parts. It improves abrasion resistance, chemical stability, and finish quality for flexible prototypes and end-use elastomeric components. The coating is particularly useful for parts printed in EL and FL families that must endure repeated mechanical stress.

Ultracur3D® Colour Kit: Resin Color Customization

The Ultracur Colour Kit allows users to add pigments to compatible Ultracur bases, producing colored parts without post-painting. It works with ST, RG, and FL/EL lines, supporting colored prototypes and brand-aligned parts in production.

Compatible 3D Printing Technologies

Ultracur is formulated to work across mainstream resin printer architectures. Its process windows are designed for stable curing, strong adhesion, and clean release under different light engines.

Stereolithography (SLA)

In Stereolithography (SLA) systems, Ultracur rigid and tough grades deliver excellent surface resolution and dimensional stability. The low shrinkage chemistry helps users achieve industry-leading accuracy in parts requiring tight tolerances, and post-curing preserves high stiffness over time.

Digital Light Processing (DLP)

Ultracur also supports Digital Light Processing (DLP) printers, where uniform layer exposure is critical. Tough and rigid grades are widely used for accurate production runs because the Reactive Urethane Photopolymers cure fast while keeping strength retention stable.

Liquid Crystal Display (LCD)

LCD resin printers benefit from Ultracur’s stable viscosity and predictable cure depth. Whether printing structural rigid parts or flexible elastomeric pieces, users can maintain consistent profiles and reduce print failures caused by overexposure or peel stress.

Engineering and Simulation Services

BASF extends Ultracur beyond resin supply into engineering support. These services help teams validate designs and optimize their additive workflows for production use.

Ultrasim® 3D Services: Simulation, Testing, and Optimization

Ultrasim® 3D services provide simulation and testing support so users can understand how Ultracur parts behave under real loads. BASF offers printing material validation, mechanical and thermal testing, and parameter optimization to reduce trial-and-error.

Lattice Design and Simulation (FEA)

Forward AM supports lattice modeling and finite element analysis for lightweight parts and energy-absorbing structures. Combining RG and ST resins with lattice simulation lets users build robust prototypes that still meet weight constraints and mechanical targets.

Testing for Additive Manufacturing (TfAM)

Testing for Additive Manufacturing (TfAM) verifies mechanical, thermal, and long-term reliability in Ultracur parts. It is used when companies require certified repeatability for high-performance applications such as tooling, small-series production, or medical modeling.

Sustainability and Cost Analysis Services

BASF also provides cost and sustainability analysis to help teams compare additive output with traditional manufacturing. This matters for selecting printing materials that balance performance with total cost of ownership in production.

Choosing the Right Ultracur3D® Material

Material selection should start from mechanical needs, then move to process fit. Ultracur gives users a broad set of options, but each resin family targets a specific performance window.

Matching Material Properties to Application Requirements

If stiffness and dimensional control matter most, choose a Rigid Line resin like RG 35 or RG 1100. For extreme stiffness and higher temperature performance, Ultracur3D® RG 3280 is ideal. If impact resistance and general-purpose use are required, the Tough Line with ST 45 provides tough multi-purpose resins that handle daily mechanical stress. For soft parts, the Flexible/Elastomeric Line with EL 60, EL 4000, and FL 300 supports elastic output.

Considerations for Print Technology Compatibility

Ultracur resins are compatible with SLA, DLP, and LCD printers, but each platform has different light behavior. Always start from validated profiles, then fine-tune exposure for your machine. High-filled rigid resins may need slightly longer exposure, while flexible resins often require slower lift behavior to protect fine structures.

Balancing Performance, Cost, and Sustainability

For prototypes moving into use, higher-cost rigid or ceramic-filled options can save money by avoiding failures and rework. For broad prototyping, daylight grades and multi-purpose ST resins reduce cost per part while keeping acceptable mechanical performance.

Future Trends in BASF Ultracur3D® Development

Innovations in Photopolymer Chemistry

Forward AM continues to refine Reactive Urethane Photopolymers to deliver faster curing, improved thermal stability, and lower odor without losing mechanical performance. Expect further developments in filled systems, elastomeric rebound, and resins tuned for higher-throughput industrial printers.

Expanding Applications Across Industries

Ultracur is increasingly used in automotive tooling, electronics fixtures, industrial housings, medical modeling, and consumer product prototypes. As resin printers become more production-ready, BASF’s high-performance resins are positioned to cover more end-use demand where excellent strength and repeatability are essential.

BASF’s Role in Driving Additive Manufacturing Forward

As one of the leading chemical manufacturers in additive materials, basf uses the Ultracur platform to push production-grade photopolymers into mainstream workflow. With strong material R&D and engineering services, basf supports companies aiming to replace traditional machining for short runs and tooling parts using Ultracur printing materials produced for automation and speed.

Frequently asked questions (FAQ)

What are Ultracur3D® Photopolymers used for?

Ultracur3D® Photopolymers are designed for high-performance applications such as functional prototypes, tooling, fixtures, elastic components, and dental model production. Their reactive urethane base provides mechanical stability for real-world use.

Which Ultracur resin should I choose for strong rigid parts?

For rigid structural parts, start with RG 35 or RG 1100 from the Rigid Line. If you need extreme stiffness and better heat resistance, select Ultracur3D® RG 3280.

Is ST 45 suitable for impact-loaded prototypes?

Yes. ST 45 is a core Tough Line material and a proven Tough Resin for prototypes and end-use components requiring excellent strength and high impact resistance.

What Ultracur materials work for flexible parts?

Flexible parts are best made with the Flexible/Elastomeric Line. FL 300 offers flexibility with high elongation, EL 60 provides soft elastic rebound, and EL 4000 gives tougher elastomeric performance for durable flexible components.

Do Ultracur resins work on SLA, DLP, and LCD printers?

Yes. Ultracur is compatible with Stereolithography (SLA), Digital Light Processing (DLP), and LCD printers. Users should begin with validated exposure profiles and then tune for their specific machine and resin type.

How can I improve surface finish and color options on Ultracur parts?

Use Ultracur supplementary products. Ultracur3D® Coat F+ improves durability and finish on flexible prints, and the Ultracur Colour Kit enables color customization across several Ultracur resin families.