Toray announced in February 2026 the development of "Trepearl PA12," a highly spherical polyamide 12 (PA12) powder designed for powder bed fusion (PBF) 3D printers. By leveraging its proprietary particle-shaping technology, the company has more than doubled impact strength while reducing surface roughness to approximately one-third of that of conventional materials. Sample shipments to select customers began in January 2026.

Enhancing Durability and Surface Finish

In molded parts, Trepearl PA12 achieves a surface roughness of approximately 7 μm and a Charpy impact strength of 50 kJ/m² (unnotched), attributable to improved sintering and fusion behavior enabled by uniformly packed, high-density spherical particles. It is expected to be suitable for a wide range of applications, from prototyping to functional components, particularly where durability and airtightness are required. The material is also compatible with existing 3D printing systems.

Toray’s spherical particle technology builds on its long-standing expertise in polyamide polymerization and resin processing. The company previously commercialized "Trepearl PA6," heat-resistant, highly spherical PA6 powder, which has seen adoption in applications such as automotive components, office furniture, and power tools. Trepearl PA12 extends this technology platform to PA12.

Overcoming Conventional Powder Limitations

Powder bed fusion (PBF) 3D printers are predominantly used in industrial applications. Among resin powders, PA12 is estimated to account for roughly 70% of the market due to its suitability for low-temperature sintering. However, conventional PA12 powders typically consist of irregularly shaped particles, which limits packing uniformity. This often results in rougher part surfaces and necessitates post-processing steps such as polishing. In addition, inter-particle gaps can generate microvoids within molded parts, reducing density and preventing the material from fully realizing its intrinsic mechanical properties.

The development of resin materials for 3D printers remains an active area within the material industry. Toray entered this space with "Tremil PPS resin powder" in 2017, followed by Trepearl PA6 in 2022. The addition of Trepearl PA12 further expands its product portfolio.

In March 2026, Asahi Kasei began commercializing "KARAKSA-F," a PA-based filament reinforced with cellulose nanofibers (CNF). The material offers high strength and heat resistance, making it suitable for industrial applications. The company is also collaborating with Italy’s Aquafil to develop 3D printing materials based on “ECONYL,” a recycled PA6 derived from nylon waste, targeting automotive and aerospace applications.

Germany's BASF, through its subsidiary BASF 3D Printing Solutions, offers a wide range of filaments for Fused Deposition Modeling (FDM), including "Ultrafuse PAHT CF15," which contains 15% reinforcement in a polyamide matrix. While other material manufacturers differentiate themselves through the use of reinforcing fibers and recycled raw materials, Toray is creating new value by optimizing particle morphology—an approach that directly addresses fundamental performance limitations in powder-based 3D printing.