engineering-skills/additive-manufacturing/references/materials-db.json

{
  "_meta": {
    "version": "2.0",
    "description": "AM Materials Database — mechanical properties, roughness by orientation, post-processing for Ra targets, selection guide. Values from literature and datasheets. Always verify with the specific supplier datasheet.",
    "units": { "UTS": "MPa", "YS": "MPa", "E": "GPa", "elongation": "%", "HDT": "°C", "T_max_service": "°C", "density": "g/cm³", "Ra": "µm", "accuracy": "mm", "shrinkage": "%", "fatigue_limit": "MPa" },
    "fatigue_note": "fatigue_limit_asbuilt = fatigue limit @ 10^7 cycles, R=0.1, as-built (high scatter ±20%). fatigue_limit_HIP_machined = with HIP + surface machining, close to forged. Kf_asbuilt_side = stress concentration factor from side surface roughness (Ra 15–20µm). See references/fatigue-design.md for complete calculation.",
    "roughness_note": "Ra on typical surfaces. top_surface = parallel to the XY plane (last layer). side_XY = vertical surfaces. down_facing = lower overhang/support surfaces. As-built values without post-processing.",
    "anisotropy_note": "anisotropy_Z_factor = UTS_Z / UTS_XY. E.g. 0.6 means the strength in the Z direction (layer stacking) is 60% of that in the XY plane."
  },

  "processes": {
    "FDM":  { "Ra_typical": [15,50], "accuracy_mm": 0.3, "supports": true,  "note": "High anisotropy. Roughness strongly depends on orientation and layer height." },
    "SLA":  { "Ra_typical": [1,6],   "accuracy_mm": 0.15,"supports": true,  "note": "UV post-cure mandatory. Best Ra among polymer processes." },
    "DLP":  { "Ra_typical": [2,8],   "accuracy_mm": 0.15,"supports": true,  "note": "Faster than SLA. Ra depends on projector resolution." },
    "SLS":  { "Ra_typical": [8,15],  "accuracy_mm": 0.3, "supports": false, "note": "Powder acts as support. Good isotropy. Significant shrinkage (~3.5%)." },
    "MJF":  { "Ra_typical": [6,12],  "accuracy_mm": 0.25,"supports": false, "note": "Slightly better finish than SLS. Full-color available." },
    "LPBF": { "Ra_typical": [8,20],  "accuracy_mm": 0.1, "supports": true,  "note": "Metal supports are critical. Stress relief mandatory before removal." },
    "EBM":  { "Ra_typical": [20,35], "accuracy_mm": 0.2, "supports": true,  "note": "Higher Ra than LPBF. Vacuum chamber. Reduced thermal gradients." },
    "BJT":  { "Ra_typical": [4,10],  "accuracy_mm": 0.4, "supports": false, "note": "Post-print sintering. Shrinkage ~20%. Tolerances worse than LPBF." }
  },

  "polymers": [
    {
      "id": "PLA",
      "name": "PLA (Polylactic Acid)",
      "family": "standard_fdm", "processes": ["FDM"],
      "mechanical": { "UTS_min": 50, "UTS_max": 65, "E_min": 3.3, "E_max": 3.8, "elongation_min": 3, "elongation_max": 6, "anisotropy_Z_factor": 0.55 },
      "thermal": { "HDT_min": 52, "HDT_max": 65, "T_max_service": 52 },
      "surface_roughness": {
        "top_surface":  { "Ra_min": 5,  "Ra_max": 15 },
        "side_XY":      { "Ra_min": 15, "Ra_max": 35 },
        "down_facing":  { "Ra_min": 25, "Ra_max": 60, "note": "support interface" },
        "Ra_asbuilt_typical": 25,
        "postprocess_achievable": {
          "sanding_400":  { "Ra_min": 3,   "Ra_max": 8  },
          "sanding_800":  { "Ra_min": 1.5, "Ra_max": 4  },
          "primer_sand":  { "Ra_min": 0.8, "Ra_max": 2  }
        }
      },
      "flags": { "biocompatible": false, "uv_resistant": false, "food_safe_possible": false, "predry_required": false, "enclosure_required": false, "supports_needed": true },
      "chemical_resistance": { "acids_dilute": "good", "bases_dilute": "good", "solvents_organic": "poor", "fuels": "poor", "UV_outdoor": "poor" },
      "shrinkage": { "min": 0.1, "max": 0.3 },
      "cost_relative": 1, "print_difficulty": "easy",
      "variants": ["PLA+", "PLA-CF (+20% UTS, hardened steel nozzle mandatory)"],
      "applications": ["visual prototypes", "concept models", "non-structural parts", "gadgets"],
      "warnings": ["biodegradable — avoid prolonged humid/hot environments", "no UV outdoor", "brittle under impact"],
      "postprocessing_sequence": ["support removal", "wet sanding 120→240→400→800", "primer surfacer", "painting or clear coat"]
    },
    {
      "id": "PETG",
      "name": "PETG (Polyethylene Terephthalate Glycol)",
      "family": "standard_fdm", "processes": ["FDM"],
      "mechanical": { "UTS_min": 50, "UTS_max": 55, "E_min": 2.1, "E_max": 2.5, "elongation_min": 50, "elongation_max": 200, "anisotropy_Z_factor": 0.65 },
      "thermal": { "HDT_min": 75, "HDT_max": 80, "T_max_service": 75 },
      "surface_roughness": {
        "top_surface": { "Ra_min": 5, "Ra_max": 12 },
        "side_XY":     { "Ra_min": 12,"Ra_max": 30 },
        "down_facing": { "Ra_min": 20,"Ra_max": 50 },
        "Ra_asbuilt_typical": 20,
        "postprocess_achievable": {
          "sanding_400": { "Ra_min": 2,   "Ra_max": 6  },
          "sanding_800": { "Ra_min": 1.0, "Ra_max": 3  }
        }
      },
      "flags": { "biocompatible": false, "uv_resistant": false, "food_safe_possible": true, "food_safe_note": "depends on pigments and additives from supplier", "predry_required": false, "enclosure_required": false, "supports_needed": true },
      "chemical_resistance": { "acids_dilute": "excellent", "bases_dilute": "excellent", "alcohols": "excellent", "solvents_organic": "moderate", "fuels": "good" },
      "shrinkage": { "min": 0.1, "max": 0.3 },
      "cost_relative": 1.2, "print_difficulty": "moderate",
      "warnings": ["high stringing — temperature and retraction are critical", "sticks heavily to bed — use release agent on glass"],
      "postprocessing_sequence": ["support removal", "sanding 180→400→800", "polyurethane primer + painting"]
    },
    {
      "id": "ABS",
      "name": "ABS (Acrylonitrile Butadiene Styrene)",
      "family": "engineering_fdm", "processes": ["FDM"],
      "mechanical": { "UTS_min": 40, "UTS_max": 50, "E_min": 2.0, "E_max": 2.5, "elongation_min": 5, "elongation_max": 25, "anisotropy_Z_factor": 0.55 },
      "thermal": { "HDT_min": 90, "HDT_max": 100, "T_max_service": 90 },
      "surface_roughness": {
        "top_surface": { "Ra_min": 5, "Ra_max": 15 },
        "side_XY":     { "Ra_min": 15,"Ra_max": 40 },
        "down_facing": { "Ra_min": 25,"Ra_max": 55 },
        "Ra_asbuilt_typical": 25,
        "postprocess_achievable": {
          "acetone_smoothing": { "Ra_min": 1.5, "Ra_max": 5,   "note": "alters dimensions ±0.1–0.3mm" },
          "sanding_800":       { "Ra_min": 2,   "Ra_max": 6   }
        }
      },
      "flags": { "uv_resistant": false, "predry_required": false, "enclosure_required": true, "enclosure_temp_min": 40, "supports_needed": true },
      "shrinkage": { "min": 0.5, "max": 1.5 },
      "cost_relative": 1.2, "print_difficulty": "difficult",
      "warnings": ["severe warping without enclosure", "toxic fumes — ventilation mandatory"],
      "postprocessing_sequence": ["support removal", "acetone smoothing OR sanding 120→400→800", "primer + painting"]
    },
    {
      "id": "ASA",
      "name": "ASA (Acrylonitrile Styrene Acrylate)",
      "family": "engineering_fdm", "processes": ["FDM"],
      "mechanical": { "UTS_min": 45, "UTS_max": 55, "E_min": 2.1, "E_max": 2.6, "elongation_min": 5, "elongation_max": 20, "anisotropy_Z_factor": 0.55 },
      "thermal": { "HDT_min": 90, "HDT_max": 100, "T_max_service": 90 },
      "surface_roughness": {
        "top_surface": { "Ra_min": 5, "Ra_max": 15 },
        "side_XY":     { "Ra_min": 15,"Ra_max": 40 },
        "Ra_asbuilt_typical": 25
      },
      "flags": { "uv_resistant": true, "predry_required": false, "enclosure_required": true, "supports_needed": true },
      "shrinkage": { "min": 0.5, "max": 1.0 },
      "cost_relative": 1.5, "print_difficulty": "difficult",
      "applications": ["outdoor parts", "automotive exterior", "signage"],
      "postprocessing_sequence": ["support removal", "sanding 180→400→800", "UV-resistant primer + painting"]
    },
    {
      "id": "PA12-FDM",
      "name": "PA12 / Nylon 12 — FDM",
      "family": "engineering_fdm", "processes": ["FDM"],
      "mechanical": { "UTS_min": 50, "UTS_max": 60, "E_min": 1.6, "E_max": 2.2, "elongation_min": 30, "elongation_max": 300, "anisotropy_Z_factor": 0.60 },
      "thermal": { "HDT_min": 120, "HDT_max": 120, "T_max_service": 110 },
      "surface_roughness": {
        "top_surface": { "Ra_min": 8, "Ra_max": 20 },
        "side_XY":     { "Ra_min": 20,"Ra_max": 45 },
        "down_facing": { "Ra_min": 30,"Ra_max": 60 },
        "Ra_asbuilt_typical": 30
      },
      "flags": { "predry_required": true, "predry_conditions": "70–80°C / 4–8h before each session", "enclosure_required": true, "supports_needed": true },
      "chemical_resistance": { "fuels": "excellent", "oils": "excellent", "bases": "excellent", "acids_conc": "moderate" },
      "shrinkage": { "min": 1.0, "max": 2.0 },
      "cost_relative": 2.0, "print_difficulty": "difficult",
      "applications": ["gears", "snap-fits", "automotive parts", "mechanical components"],
      "warnings": ["hygroscopic — pre-dry MANDATORY before each session"]
    },
    {
      "id": "PC",
      "name": "PC (Polycarbonate)",
      "family": "high_performance_fdm", "processes": ["FDM"],
      "mechanical": { "UTS_min": 55, "UTS_max": 70, "E_min": 2.3, "E_max": 2.8, "elongation_min": 100, "elongation_max": 120, "anisotropy_Z_factor": 0.60 },
      "thermal": { "HDT_min": 110, "HDT_max": 130, "T_max_service": 115 },
      "surface_roughness": {
        "top_surface": { "Ra_min": 5, "Ra_max": 15 },
        "side_XY":     { "Ra_min": 15,"Ra_max": 35 },
        "Ra_asbuilt_typical": 20,
        "postprocess_achievable": {
          "sanding_1200_polish": { "Ra_min": 0.1, "Ra_max": 0.5, "note": "polishing for transparency" }
        }
      },
      "flags": { "transparent": true, "predry_required": true, "predry_conditions": "80–90°C / 4–6h", "enclosure_required": true, "enclosure_temp_min": 60, "nozzle_temp_min": 260, "nozzle_temp_max": 290, "supports_needed": true },
      "shrinkage": { "min": 0.5, "max": 0.8 },
      "cost_relative": 2.5, "print_difficulty": "very difficult",
      "applications": ["optical components", "electronic housings", "transparent covers", "thermal fixtures"]
    },
    {
      "id": "PEEK-FDM",
      "name": "PEEK (Polyether Ether Ketone) — FDM",
      "family": "ultra_high_performance", "processes": ["FDM"],
      "mechanical": { "UTS_min": 90, "UTS_max": 105, "E_min": 3.5, "E_max": 4.2, "elongation_min": 30, "elongation_max": 50, "anisotropy_Z_factor": 0.70 },
      "thermal": { "HDT_min": 250, "HDT_max": 260, "T_max_service": 240 },
      "surface_roughness": {
        "side_XY": { "Ra_min": 15, "Ra_max": 40 },
        "Ra_asbuilt_typical": 25,
        "postprocess_achievable": {
          "machining_CNC": { "Ra_min": 0.4, "Ra_max": 1.6 }
        }
      },
      "flags": { "biocompatible": true, "biocompat_standards": ["ISO 10993", "USP Class VI"], "uv_resistant": true, "predry_required": true, "predry_conditions": "120°C / 4h", "enclosure_required": true, "enclosure_temp_min": 90, "nozzle_allMetal_required": true, "supports_needed": true },
      "chemical_resistance": { "general": "excellent" },
      "cost_relative": 30, "cost_EUR_per_kg": "200–400", "print_difficulty": "extreme",
      "variants": ["CF-PEEK (+30% E, -ductility)"],
      "applications": ["medical", "aerospace", "high-temperature chemical", "spinal implants"],
      "warnings": ["all-metal hot end mandatory (no PTFE >260°C)", "slow cooling inside enclosure"]
    },
    {
      "id": "TPU-FDM",
      "name": "TPU / TPE elastomers — FDM",
      "family": "flexible_fdm", "processes": ["FDM"],
      "mechanical": { "UTS_min": 10, "UTS_max": 40, "elongation_min": 300, "elongation_max": 600 },
      "thermal": { "HDT_min": 70, "HDT_max": 85, "T_max_service": 75 },
      "shore": { "min": 85, "max": 98, "scale": "A" },
      "surface_roughness": {
        "side_XY": { "Ra_min": 15, "Ra_max": 35 },
        "Ra_asbuilt_typical": 22
      },
      "flags": { "flexible": true, "predry_required": false, "enclosure_required": false, "direct_drive_recommended": true, "supports_needed": true },
      "cost_relative": 2.0, "print_difficulty": "moderate",
      "warnings": ["reduced or zero retraction with direct drive", "bowden extruder: severe underextrusion", "slow printing (20–35 mm/s max perimeters)"]
    },
    {
      "id": "CF-short-FDM",
      "name": "Short-fiber composites — PA-CF, PETG-CF, PC-CF",
      "family": "composite_fdm", "processes": ["FDM"],
      "mechanical": { "UTS_note": "+20–40% vs base polymer", "E_note": "+30–60% vs base polymer", "elongation_note": "reduced — more brittle" },
      "surface_roughness": {
        "side_XY": { "Ra_min": 15, "Ra_max": 45 },
        "Ra_asbuilt_typical": 30
      },
      "flags": { "hardened_nozzle_required": true, "predry_required": "depends on base polymer", "enclosure_required": "depends on base polymer" },
      "cost_relative": 2.5, "print_difficulty": "moderate-difficult",
      "warnings": ["brass nozzles wear out within a few hours — hardened steel or ruby nozzle mandatory"]
    },
    {
      "id": "Onyx-ContinuousFiber",
      "name": "Onyx + Continuous Fiber — Markforged",
      "family": "composite_continuous_fiber", "processes": ["FDM-Markforged"],
      "mechanical": { "UTS_max_CF": 800, "E_max_CF_GPa": 70, "UTS_onyx": 30, "note": "Continuous CF oriented along load direction" },
      "thermal": { "T_max_service": 105 },
      "surface_roughness": { "side_XY": { "Ra_min": 10, "Ra_max": 25 }, "Ra_asbuilt_typical": 20 },
      "flags": { "markforged_only": true, "enclosure_required": true },
      "reinforcement_options": ["Carbon Fiber", "Kevlar", "HSHT Fiberglass"],
      "cost_relative": 8, "print_difficulty": "moderate (dedicated machine)",
      "applications": ["structural aluminum replacement", "fixtures", "tooling", "robot end-effectors"],
      "warnings": ["Markforged machines only", "not repairable with standard FDM"]
    },
    {
      "id": "PA12-SLS",
      "name": "PA12 SLS (EOS PA2200, Duraform PA)",
      "family": "sls_powder", "processes": ["SLS"],
      "mechanical": { "UTS_min": 45, "UTS_max": 50, "E_min": 1.7, "E_max": 1.9, "elongation_min": 18, "elongation_max": 23, "anisotropy_Z_factor": 0.90 },
      "thermal": { "HDT_min": 163, "HDT_max": 163, "T_max_service": 150 },
      "surface_roughness": {
        "top_surface":  { "Ra_min": 6,  "Ra_max": 12 },
        "side_XY":      { "Ra_min": 8,  "Ra_max": 15 },
        "down_facing":  { "Ra_min": 8,  "Ra_max": 18, "note": "SLS: no support interface" },
        "Ra_asbuilt_typical": 10,
        "postprocess_achievable": {
          "bead_blast":      { "Ra_min": 4, "Ra_max": 8  },
          "vibratory":       { "Ra_min": 2, "Ra_max": 5  },
          "SLS_coating":     { "Ra_min": 3, "Ra_max": 6  },
          "machining":       { "Ra_min": 0.4,"Ra_max": 1.6 }
        }
      },
      "fatigue": {
        "fatigue_limit_asbuilt_min": 18, "fatigue_limit_asbuilt_max": 25,
        "fatigue_reference_cycles": "10^6, R=0.1",
        "fatigue_anisotropy_Z_XY_asbuilt": 0.92,
        "note": "Polymer with the best fatigue behavior among AM processes. Moisture-sensitive: store at humidity < 50% RH. Over-aged powder reduces elongation and fatigue."
      },
      "flags": { "supports_needed": false, "isotropic": true, "predry_required": false },
      "chemical_resistance": { "fuels": "excellent", "oils": "excellent", "acids_dilute": "good" },
      "shrinkage": { "min": 3.0, "max": 4.0, "axis_note": "isotropic ~3.5% XY and Z" },
      "accuracy": "±0.3mm", "cost_relative": 5,
      "applications": ["functional parts", "complex geometries", "series 10–200 pcs", "prosthetics"],
      "warnings": ["shrinkage 3.5–4% — compensate in CAD", "recycled powder max 50%"],
      "postprocessing_sequence": ["breakout + cleaning (compressed air + blasting)", "standard bead blast", "dyeing if color is required", "coating if sealing is required"]
    },
    {
      "id": "PA12-MJF",
      "name": "PA12 MJF (HP Multi Jet Fusion)",
      "family": "mjf_powder", "processes": ["MJF"],
      "mechanical": { "UTS_min": 48, "UTS_max": 53, "E_min": 1.8, "E_max": 2.0, "elongation_min": 15, "elongation_max": 20, "anisotropy_Z_factor": 0.92 },
      "thermal": { "HDT_min": 163, "HDT_max": 165, "T_max_service": 150 },
      "surface_roughness": {
        "top_surface":  { "Ra_min": 5,  "Ra_max": 10 },
        "side_XY":      { "Ra_min": 6,  "Ra_max": 12 },
        "Ra_asbuilt_typical": 8,
        "postprocess_achievable": {
          "bead_blast":  { "Ra_min": 3, "Ra_max": 7 },
          "vibratory":   { "Ra_min": 2, "Ra_max": 4 }
        }
      },
      "flags": { "supports_needed": false, "color_available": true, "color_note": "Full color HP MJF 5200" },
      "shrinkage": { "min": 3.0, "max": 4.0 },
      "accuracy": "±0.2–0.3mm", "cost_relative": 5,
      "packing_density_optimal": "8–12%",
      "applications": ["medium-volume production", "colored parts", "series 50–500 pcs"]
    },
    {
      "id": "PA11-SLS",
      "name": "PA11 SLS",
      "family": "sls_powder", "processes": ["SLS"],
      "mechanical": { "UTS_min": 48, "UTS_max": 53, "E_min": 1.6, "E_max": 1.8, "elongation_min": 40, "elongation_max": 50, "anisotropy_Z_factor": 0.90 },
      "thermal": { "T_max_service": 120 },
      "surface_roughness": {
        "side_XY": { "Ra_min": 8, "Ra_max": 16 },
        "Ra_asbuilt_typical": 11
      },
      "flags": { "supports_needed": false, "bio_based": true, "bio_based_source": "castor oil" },
      "shrinkage": { "min": 2.5, "max": 3.5 }, "cost_relative": 6,
      "applications": ["automotive components", "high-impact parts", "prosthetics and orthotics"],
      "notes": "Prefer over PA12 when: elongation >30% is required, repeated impacts, presence of notches"
    },
    {
      "id": "PA12-CF-SLS",
      "name": "PA12-CF / PA12-GF SLS",
      "family": "sls_powder_composite", "processes": ["SLS"],
      "mechanical": { "UTS_min": 50, "UTS_max": 55, "E_min": 3.5, "E_max": 4.5, "elongation_min": 5, "elongation_max": 10 },
      "thermal": { "HDT_min": 180, "HDT_max": 200, "T_max_service": 175 },
      "surface_roughness": { "side_XY": { "Ra_min": 9, "Ra_max": 18 }, "Ra_asbuilt_typical": 12 },
      "flags": { "supports_needed": false },
      "cost_relative": 7,
      "applications": ["rigid structural parts", "elevated temperature", "technical housings"]
    },
    {
      "id": "TPU-SLS",
      "name": "TPU SLS (BASF Ultrasint TPU)",
      "family": "sls_flexible", "processes": ["SLS"],
      "mechanical": { "UTS_min": 8, "UTS_max": 12, "elongation_min": 350, "elongation_max": 500 },
      "shore": { "min": 88, "max": 92, "scale": "A" },
      "surface_roughness": { "side_XY": { "Ra_min": 8, "Ra_max": 16 }, "Ra_asbuilt_typical": 12 },
      "flags": { "supports_needed": false, "flexible": true },
      "cost_relative": 8,
      "applications": ["shoe soles", "dampers", "flexible seals", "functional lattice"]
    },
    {
      "id": "Resin-Standard",
      "name": "Standard ABS-like Resin — SLA/DLP",
      "family": "resin_standard", "processes": ["SLA", "DLP", "MSLA"],
      "mechanical": { "UTS_min": 50, "UTS_max": 70, "E_min": 2.5, "E_max": 3.5, "elongation_min": 5, "elongation_max": 15 },
      "thermal": { "HDT_min": 55, "HDT_max": 70, "T_max_service": 55 },
      "surface_roughness": {
        "top_surface":  { "Ra_min": 1.0, "Ra_max": 3.0 },
        "side_XY":      { "Ra_min": 2.0, "Ra_max": 6.0, "note": "visible stair-stepping with layer >50µm" },
        "down_facing":  { "Ra_min": 3.0, "Ra_max": 8.0, "note": "touchpoint marks from supports" },
        "Ra_asbuilt_typical": 3,
        "postprocess_achievable": {
          "sanding_800":    { "Ra_min": 0.4, "Ra_max": 1.0 },
          "polish":         { "Ra_min": 0.05,"Ra_max": 0.2 }
        }
      },
      "flags": { "supports_needed": true, "post_cure_required": true, "IPA_wash_required": true, "uv_resistant": false },
      "shrinkage": { "min": 0.1, "max": 0.3 }, "accuracy": "±0.1–0.15mm",
      "cost_relative": 2, "print_difficulty": "easy",
      "warnings": ["UV photodegradation — outdoor yellowing", "post-cure mandatory for final properties"],
      "postprocessing_sequence": ["IPA wash 10–15 min", "air drying 5 min", "UV post-curing 900–1200 mJ/cm²", "support removal", "sanding if Ra <2µm is required", "UV-stable clear coat"]
    },
    {
      "id": "Resin-HighTemp",
      "name": "High-Temp Resin — SLA/DLP",
      "family": "resin_hightemp", "processes": ["SLA", "DLP"],
      "mechanical": { "UTS_min": 60, "UTS_max": 80, "elongation_min": 2, "elongation_max": 6 },
      "thermal": { "HDT_min": 160, "HDT_max": 280, "T_max_service": 160 },
      "surface_roughness": { "side_XY": { "Ra_min": 2, "Ra_max": 6 }, "Ra_asbuilt_typical": 3 },
      "flags": { "supports_needed": true, "post_cure_required": true, "brittle": true },
      "cost_relative": 5,
      "applications": ["small-series injection molds", "process fixtures", "aerodynamic testing"]
    },
    {
      "id": "Resin-Flexible",
      "name": "Flexible/Elastic Resin — SLA/DLP",
      "family": "resin_flexible", "processes": ["SLA", "DLP"],
      "shore": { "min": 40, "max": 80, "scale": "A" },
      "surface_roughness": { "side_XY": { "Ra_min": 2, "Ra_max": 8 }, "Ra_asbuilt_typical": 4 },
      "flags": { "supports_needed": true, "post_cure_required": true, "flexible": true },
      "cost_relative": 3,
      "warnings": ["mechanical properties lower than TPU SLS"]
    },
    {
      "id": "Resin-Dental-Medical",
      "name": "Dental/Medical Resin — SLA/DLP",
      "family": "resin_medical", "processes": ["SLA", "DLP"],
      "mechanical": { "UTS_min": 60, "UTS_max": 80 },
      "surface_roughness": { "side_XY": { "Ra_min": 1, "Ra_max": 4 }, "Ra_asbuilt_typical": 2 },
      "flags": { "biocompatible": true, "biocompat_standards": ["ISO 10993", "class IIa/IIb"], "supports_needed": true, "post_cure_required": true },
      "cost_relative": 8,
      "applications": ["anatomical models", "surgical guides", "aligners", "temporary devices"]
    },
    {
      "id": "Resin-Ceramic",
      "name": "Ceramic Resin Alumina/Zirconia — SLA/DLP",
      "family": "ceramic_vat", "processes": ["SLA", "DLP"],
      "mechanical": { "UTS_min": 200, "UTS_max": 600, "note": "after sintering" },
      "surface_roughness": {
        "Ra_asbuilt_typical": 2,
        "postprocess_achievable": {
          "after_sintering":  { "Ra_min": 0.5, "Ra_max": 3   },
          "after_grinding":   { "Ra_min": 0.05,"Ra_max": 0.4 }
        }
      },
      "flags": { "biocompatible": true, "supports_needed": true, "multi_step_process": true },
      "shrinkage": { "min": 20, "max": 25, "note": "ALWAYS COMPENSATE IN CAD" },
      "cost_relative": 15,
      "applications": ["zirconia dental prosthetics", "technical alumina components", "ceramic insulators"],
      "warnings": ["shrinkage 20–25% — compensation in CAD is mandatory", "multi-step process: print → debinding → sintering"],
      "postprocessing_sequence": ["IPA wash", "UV post-cure", "debinding 200–600°C ramp 1–5°C/min", "pre-sintering 1000°C/2h", "sintering 1450–1600°C/2h", "optional HIP", "grinding/lapping functional surfaces"]
    }
  ],

  "metals": [
    {
      "id": "AlSi10Mg",
      "name": "AlSi10Mg",
      "family": "aluminum_alloy", "processes": ["LPBF"],
      "mechanical": {
        "UTS_asbuilt_min": 400, "UTS_asbuilt_max": 470,
        "UTS_SR_min": 350, "UTS_SR_max": 420,
        "YS_min": 240, "YS_max": 280, "E_min": 70, "E_max": 75,
        "elongation_min": 6, "elongation_max": 11, "anisotropy_Z_factor": 0.85
      },
      "thermal": { "T_max_service": 150 }, "density": 2.68,
      "surface_roughness": {
        "top_surface":  { "Ra_min": 5,  "Ra_max": 15 },
        "side_XY":      { "Ra_min": 8,  "Ra_max": 20 },
        "down_facing":  { "Ra_min": 15, "Ra_max": 35 },
        "Ra_asbuilt_typical": 12,
        "postprocess_achievable": {
          "bead_blast":       { "Ra_min": 4,   "Ra_max": 8   },
          "vibratory":        { "Ra_min": 2,   "Ra_max": 5   },
          "shot_peen":        { "Ra_min": 3,   "Ra_max": 7,  "note": "introduces compressive stress — improves fatigue" },
          "machining":        { "Ra_min": 0.4, "Ra_max": 1.6 },
          "electropolish":    { "Ra_min": 0.5, "Ra_max": 2.0, "note": "variable results on Al" },
          "anodizing":        { "note": "does not change Ra — protection and color" }
        }
      },
      "flags": { "biocompatible": false, "supports_needed": true },
      "accuracy": "±0.05–0.1mm", "shrinkage": { "min": 0.3, "max": 0.5 }, "build_atmosphere": "Nitrogen",
      "heat_treatment": {
        "stress_relief": { "temp_C": 300, "time_h": 2, "atmosphere": "air or argon", "mandatory": true, "timing": "BEFORE removal from build plate" },
        "T6": { "mandatory": false, "note": "improves ductility" }
      },
      "fatigue": {
        "fatigue_limit_asbuilt_min": 90, "fatigue_limit_asbuilt_max": 130,
        "fatigue_limit_HIP_machined_min": 120, "fatigue_limit_HIP_machined_max": 170,
        "fatigue_limit_reference_forged_6061T6": 100,
        "fatigue_anisotropy_Z_XY_asbuilt": 0.60,
        "fatigue_anisotropy_Z_XY_HIP": 0.90,
        "Kf_asbuilt_side_Ra15_20": 1.7,
        "shot_peen_improvement_pct": "15–25",
        "note": "Very sensitive to porosity and powder humidity. With HIP it approaches forged 6061-T6 performance."
      },
      "machinability": "excellent", "cost_relative": 3,
      "applications": ["lightweight structural parts", "housings", "aero/auto brackets", "heat sinks", "manifolds"],
      "warnings": ["no applications >150°C", "stress relief before build plate removal — critical"],
      "postprocessing_sequence": ["stress relief 300°C/2h", "build plate removal (EDM/saw)", "support removal", "machining critical surfaces", "surface finishing", "anodizing if required"]
    },
    {
      "id": "Scalmalloy",
      "name": "Scalmalloy® (AlMgScZr)",
      "family": "aluminum_advanced", "processes": ["LPBF"],
      "mechanical": { "UTS_min": 520, "UTS_max": 540, "YS_min": 470, "YS_max": 490, "elongation_min": 13, "elongation_max": 16 },
      "density": 2.67,
      "surface_roughness": { "side_XY": { "Ra_min": 8, "Ra_max": 20 }, "Ra_asbuilt_typical": 12 },
      "flags": { "supports_needed": true },
      "heat_treatment": { "T6": { "mandatory": true } },
      "cost_relative": 12, "cost_note": "~3–5× AlSi10Mg",
      "applications": ["high-performance structural parts for aero/motorsport/UAV"],
      "warnings": ["very high cost — justify with performance analysis"]
    },
    {
      "id": "Ti-6Al-4V",
      "name": "Ti-6Al-4V Grade 23 (ELI)",
      "family": "titanium_alloy", "processes": ["LPBF", "EBM"],
      "mechanical": {
        "UTS_LPBF_min": 900, "UTS_LPBF_max": 1100,
        "UTS_EBM_min": 830,  "UTS_EBM_max": 1000,
        "YS_min": 800, "YS_max": 1000, "E_min": 110, "E_max": 120,
        "elongation_min": 8, "elongation_max": 15, "anisotropy_Z_factor": 0.88
      },
      "thermal": { "T_max_service": 315 }, "density": 4.43,
      "surface_roughness": {
        "top_surface":  { "Ra_min": 5,  "Ra_max": 15 },
        "side_XY":      { "Ra_min": 8,  "Ra_max": 20 },
        "down_facing":  { "Ra_min": 20, "Ra_max": 40 },
        "Ra_asbuilt_typical": 14,
        "postprocess_achievable": {
          "machining":          { "Ra_min": 0.4, "Ra_max": 1.6 },
          "electropolish":      { "Ra_min": 0.5, "Ra_max": 2.0 },
          "shot_peen":          { "Ra_min": 3,   "Ra_max": 8   },
          "machining_surgical": { "Ra_min": 0.2, "Ra_max": 0.8, "note": "implant surgical surfaces" }
        }
      },
      "flags": { "biocompatible": true, "biocompat_standards": ["ISO 10993"], "supports_needed": true },
      "accuracy": "±0.05–0.1mm", "shrinkage": { "min": 0.2, "max": 0.4 }, "build_atmosphere": "Argon",
      "heat_treatment": {
        "stress_relief": { "temp_C": 650, "time_h": 3, "atmosphere": "vacuum or argon", "mandatory": true },
        "HIP":           { "temp_C": 900, "pressure_MPa": 150, "time_h": 3, "mandatory_for": "biomedical, fatigue-critical" },
        "annealing":     { "temp_C": 790, "time_h": 2, "mandatory": false }
      },
      "fatigue": {
        "fatigue_limit_asbuilt_min": 200, "fatigue_limit_asbuilt_max": 320,
        "fatigue_limit_HIP_machined_min": 400, "fatigue_limit_HIP_machined_max": 550,
        "fatigue_limit_reference_forged": 650,
        "fatigue_anisotropy_Z_XY_asbuilt": 0.67,
        "fatigue_anisotropy_Z_XY_HIP": 0.95,
        "Kf_asbuilt_side_Ra15_20": 2.1,
        "shot_peen_improvement_pct": "20–40",
        "note": "Huge as-built scatter (±30%). HIP + machining brings performance close to forged. For biomedical implants: HIP is mandatory."
      },
      "cost_relative": 8,
      "applications": ["orthopedic implants", "aerospace hot section", "lightweight racing structures"],
      "warnings": ["HIP mandatory for implants", "stress relief critical before support removal"],
      "postprocessing_sequence": ["stress relief 650°C/3h/vacuum", "build plate removal (EDM)", "support removal", "HIP for biomedical/fatigue-critical", "machining functional surfaces", "electropolish or passivation", "CT scan inspection (implants)"]
    },
    {
      "id": "316L",
      "name": "316L Stainless Steel",
      "family": "stainless_steel", "processes": ["LPBF", "BJT"],
      "mechanical": {
        "UTS_LPBF_min": 550, "UTS_LPBF_max": 640,
        "UTS_BJT_min": 480,  "UTS_BJT_max": 540,
        "YS_min": 400, "YS_max": 460, "E_min": 193, "E_max": 200,
        "elongation_min": 40, "elongation_max": 50
      },
      "density": 7.99,
      "surface_roughness": {
        "side_XY": { "Ra_min": 8, "Ra_max": 20 },
        "Ra_asbuilt_typical": 12,
        "postprocess_achievable": {
          "machining":       { "Ra_min": 0.4, "Ra_max": 1.6 },
          "electropolish":   { "Ra_min": 0.2, "Ra_max": 0.8, "note": "excellent on 316L — food/medical standard" },
          "shot_peen":       { "Ra_min": 3,   "Ra_max": 6   },
          "passivation":     { "note": "does not change Ra — protects against corrosion" }
        }
      },
      "flags": { "biocompatible": true, "supports_needed": true, "BJT_no_supports": true },
      "accuracy_LPBF": "±0.05–0.1mm", "accuracy_BJT": "±0.3–0.5mm post-sinter",
      "shrinkage_LPBF": { "min": 0.2, "max": 0.3 },
      "shrinkage_BJT":  { "min": 18,  "max": 22, "note": "sintering — compensate in CAD" },
      "build_atmosphere": "Nitrogen or Argon",
      "heat_treatment": {
        "stress_relief": { "temp_C": 1000, "time_h": 1.5, "atmosphere": "vacuum", "mandatory": false },
        "solution_anneal": { "temp_C": 1050, "time_h": 1, "note": "if maximum corrosion resistance is required" }
      },
      "fatigue": {
        "fatigue_limit_asbuilt_min": 180, "fatigue_limit_asbuilt_max": 220,
        "fatigue_limit_HIP_machined_min": 220, "fatigue_limit_HIP_machined_max": 260,
        "fatigue_limit_reference_forged": 220,
        "fatigue_anisotropy_Z_XY_asbuilt": 0.80,
        "fatigue_anisotropy_Z_XY_HIP": 0.96,
        "Kf_asbuilt_side_Ra15_20": 1.6,
        "shot_peen_improvement_pct": "15–25",
        "note": "As-built fatigue is almost comparable to forged material — ductile and defect-tolerant alloy. BJT: fatigue data not available, not recommended for fatigue-critical applications without HIP."
      },
      "cost_relative": 4,
      "applications": ["medical", "food-contact", "chemical", "marine"],
      "notes": "BJT is cheaper for volumes >50 pcs — looser tolerances"
    },
    {
      "id": "17-4PH",
      "name": "17-4PH (AISI 630)",
      "family": "stainless_steel_ph", "processes": ["LPBF", "BJT"],
      "mechanical": {
        "UTS_min": 1000, "UTS_max": 1300, "UTS_condition": "H900",
        "YS_min": 950, "YS_max": 1200, "elongation_min": 5, "elongation_max": 12
      },
      "density": 7.78,
      "surface_roughness": {
        "side_XY": { "Ra_min": 8, "Ra_max": 20 }, "Ra_asbuilt_typical": 12,
        "postprocess_achievable": {
          "machining": { "Ra_min": 0.4, "Ra_max": 1.6 },
          "grinding":  { "Ra_min": 0.1, "Ra_max": 0.4 }
        }
      },
      "flags": { "supports_needed": true },
      "heat_treatment": {
        "solution_anneal": { "temp_C": 1040, "time_h": 1, "atmosphere": "vacuum" },
        "aging_H900":      { "temp_C": 480, "time_h": 1, "atmosphere": "air", "mandatory": true, "warning": "MANDATORY — without aging, properties are ~40% of H900 values" }
      },
      "fatigue": {
        "fatigue_limit_H900_min": 350, "fatigue_limit_H900_max": 430,
        "fatigue_limit_reference_forged_H900": 450,
        "fatigue_anisotropy_Z_XY_asbuilt": 0.75,
        "Kf_asbuilt_side_Ra15_20": 1.7,
        "shot_peen_improvement_pct": "15–25",
        "note": "Fatigue data available only in H900 condition (aging mandatory). As-built is not an option for fatigue."
      },
      "cost_relative": 5,
      "applications": ["loaded structural parts", "molds", "tooling", "aerospace", "marine hardware"],
      "warnings": ["aging H900 is mandatory — never omit it"],
      "postprocessing_sequence": ["stress relief", "build plate + support removal", "solution anneal 1040°C/1h", "aging H900 480°C/1h/air", "machining", "grinding if Ra <0.4µm"]
    },
    {
      "id": "IN625",
      "name": "Inconel 625",
      "family": "nickel_superalloy", "processes": ["LPBF"],
      "mechanical": { "UTS_min": 900, "UTS_max": 1000, "YS_min": 600, "YS_max": 700, "elongation_min": 30, "elongation_max": 40 },
      "thermal": { "T_max_service": 980 }, "density": 8.44,
      "surface_roughness": {
        "side_XY": { "Ra_min": 10, "Ra_max": 25 }, "Ra_asbuilt_typical": 15,
        "postprocess_achievable": {
          "machining":     { "Ra_min": 0.4, "Ra_max": 1.6 },
          "electropolish": { "Ra_min": 0.5, "Ra_max": 2.0 }
        }
      },
      "flags": { "supports_needed": true }, "build_atmosphere": "Argon",
      "heat_treatment": { "stress_relief": { "temp_C": 1050, "time_h": 2, "atmosphere": "vacuum", "mandatory": true } },
      "fatigue": {
        "fatigue_limit_asbuilt_min": 280, "fatigue_limit_asbuilt_max": 380,
        "fatigue_anisotropy_Z_XY_asbuilt": 0.72,
        "Kf_asbuilt_side_Ra15_20": 1.7,
        "note": "Relatively limited data in the literature. Use with safety margin >= 2.0 for critical applications."
      },
      "cost_relative": 10,
      "applications": ["offshore chemical", "oil&gas", "engine cold sections", "marine"]
    },
    {
      "id": "IN718",
      "name": "Inconel 718",
      "family": "nickel_superalloy", "processes": ["LPBF"],
      "mechanical": {
        "UTS_min": 1000, "UTS_max": 1300, "UTS_condition": "full HT",
        "YS_min": 900, "YS_max": 1100, "elongation_min": 10, "elongation_max": 20
      },
      "thermal": { "T_max_service": 700 }, "density": 8.19,
      "surface_roughness": {
        "side_XY": { "Ra_min": 10, "Ra_max": 25 }, "Ra_asbuilt_typical": 16,
        "postprocess_achievable": {
          "machining": { "Ra_min": 0.4, "Ra_max": 1.6 },
          "grinding":  { "Ra_min": 0.1, "Ra_max": 0.4 }
        }
      },
      "flags": { "supports_needed": true }, "build_atmosphere": "Argon",
      "heat_treatment": {
        "solution_anneal": { "temp_C": 1065, "time_h": 1, "atmosphere": "vacuum" },
        "aging_step1":     { "temp_C": 720,  "time_h": 8, "atmosphere": "vacuum" },
        "aging_step2":     { "temp_C": 620,  "time_h": 8, "atmosphere": "vacuum" },
        "mandatory": true,
        "warning": "MANDATORY — without full cycle, properties are ~50% of final values. Plan with a qualified supplier."
      },
      "fatigue": {
        "fatigue_limit_fullHT_min": 350, "fatigue_limit_fullHT_max": 450,
        "fatigue_limit_reference_forged": 500,
        "fatigue_anisotropy_Z_XY_asbuilt": 0.72,
        "Kf_asbuilt_side_Ra15_20": 1.8,
        "shot_peen_improvement_pct": "15–25",
        "note": "Fatigue data available only after complete HT cycle (solution anneal + double aging). As-built: do not qualify for fatigue without HT."
      },
      "cost_relative": 12,
      "applications": ["turbines", "aerospace hot section", "high-temperature fatigue parts"],
      "warnings": ["complex and certified heat treatment — plan in advance"]
    },
    {
      "id": "CoCr",
      "name": "CoCr MP1/SP2",
      "family": "cobalt_chrome", "processes": ["LPBF", "EBM"],
      "mechanical": { "UTS_min": 1000, "UTS_max": 1200, "hardness_HRC_min": 35, "hardness_HRC_max": 45 },
      "density": 8.3,
      "surface_roughness": {
        "side_XY": { "Ra_min": 10, "Ra_max": 22 }, "Ra_asbuilt_typical": 14,
        "postprocess_achievable": {
          "machining":  { "Ra_min": 0.4, "Ra_max": 1.6 },
          "polishing":  { "Ra_min": 0.05,"Ra_max": 0.2, "note": "dental prosthetics — mirror finish" }
        }
      },
      "flags": { "biocompatible": true, "biocompat_standards": ["ISO 10993"], "supports_needed": true }, "build_atmosphere": "Argon",
      "heat_treatment": { "stress_relief": { "mandatory": true }, "HIP": { "mandatory_for": "biomedical implants" } },
      "fatigue": {
        "fatigue_limit_asbuilt_min": 500, "fatigue_limit_asbuilt_max": 600,
        "fatigue_anisotropy_Z_XY_asbuilt": 0.78,
        "Kf_asbuilt_side_Ra15_20": 1.7,
        "note": "Excellent fatigue performance for biomedical applications. HIP mandatory for implants. High UTS -> very favorable fatigue life."
      },
      "machinability": "difficult — design near-net shape", "cost_relative": 9,
      "applications": ["dental prosthetics", "orthopedic implants", "cutting tools"],
      "warnings": ["very difficult to machine post-print — minimize material removal in CAD"]
    },
    {
      "id": "Cu-pure",
      "name": "Pure copper (Cu)",
      "family": "copper", "processes": ["LPBF-green", "LPBF-blue"],
      "mechanical": { "UTS_min": 200, "UTS_max": 280, "elongation_min": 25, "elongation_max": 45 },
      "density": 8.96, "electrical_conductivity_IACS_min": 95, "thermal_conductivity_Wm_K": 380,
      "surface_roughness": { "side_XY": { "Ra_min": 10, "Ra_max": 25 }, "Ra_asbuilt_typical": 15 },
      "flags": { "supports_needed": true, "green_blue_laser_only": true },
      "cost_relative": 7,
      "applications": ["inductors", "heat exchangers", "bus bars", "electronic components"],
      "warnings": ["requires green 515nm or blue 450nm laser — IR lasers are inadequate", "not all service providers offer this technology"]
    }
  ],

  "selection_guides": {
    "by_Ra_target": {
      "Ra_less_0p4":   { "label": "Ra <0.4 µm",    "use_cases": "O-ring seats, seals, H6/h6 precision fits",                    "strategy": "any AM process + post-machining grinding/lapping" },
      "Ra_0p4_to_1p6": { "label": "Ra 0.4–1.6 µm", "use_cases": "functional mechanical surfaces, sliding fits",                  "strategy": "LPBF/SLS/SLA + CNC machining. SLA as-built + sanding 800." },
      "Ra_1p6_to_3p2": { "label": "Ra 1.6–3.2 µm", "use_cases": "semi-finished surfaces, non-critical inner surfaces",          "strategy": "SLA as-built. LPBF + vibratory or electropolish. SLS + vibratory." },
      "Ra_3p2_to_6p3": { "label": "Ra 3.2–6.3 µm", "use_cases": "non-critical functional surfaces, inner walls",                "strategy": "SLS/MJF + bead blast. LPBF + bead blast. Optimized FDM top surface." },
      "Ra_6p3_to_12p7":{ "label": "Ra 6.3–12.7 µm","use_cases": "non-functional surfaces, internal parts, prototypes",          "strategy": "FDM side surfaces. SLS as-built. LPBF as-built." },
      "Ra_greater_12p7":{"label": "Ra >12.7 µm",   "use_cases": "rough aesthetic parts, non-critical",                          "strategy": "FDM side/down-facing as-built." }
    },
    "by_temperature": [
      { "T_max_C": 55,  "materials": ["PLA", "Resin-Standard", "Resin-Flexible", "TPU-FDM"] },
      { "T_max_C": 80,  "materials": ["PETG", "TPU-FDM"] },
      { "T_max_C": 100, "materials": ["ABS", "ASA"] },
      { "T_max_C": 120, "materials": ["PA12-FDM", "PA11-SLS"] },
      { "T_max_C": 150, "materials": ["PC", "PA12-SLS", "PA12-MJF"] },
      { "T_max_C": 175, "materials": ["PA12-CF-SLS"] },
      { "T_max_C": 240, "materials": ["PEEK-FDM"] },
      { "T_max_C": 315, "materials": ["AlSi10Mg", "Ti-6Al-4V"] },
      { "T_max_C": 700, "materials": ["IN718"] },
      { "T_max_C": 980, "materials": ["IN625"] }
    ],
    "by_application": {
      "biomedical_implants":     ["Ti-6Al-4V", "CoCr", "PEEK-FDM"],
      "dental":                  ["CoCr", "Resin-Dental-Medical", "Resin-Ceramic"],
      "aerospace_structural":    ["AlSi10Mg", "Scalmalloy", "Ti-6Al-4V", "IN718", "IN625"],
      "automotive_lightweight":  ["AlSi10Mg", "PA12-SLS", "PA12-MJF", "CF-short-FDM", "Onyx-ContinuousFiber"],
      "chemical_process":        ["316L", "IN625", "Ti-6Al-4V"],
      "tooling_molds":           ["17-4PH", "Resin-HighTemp"],
      "flexible_seals":          ["TPU-FDM", "TPU-SLS", "Resin-Flexible"],
      "heat_exchangers":         ["AlSi10Mg", "Cu-pure", "IN625"],
      "outdoor_UV":              ["ASA", "PA12-SLS"],
      "optical_transparent":     ["PC", "Resin-Standard"],
      "food_contact":            ["316L", "PETG"],
      "structural_replace_Al":   ["Onyx-ContinuousFiber", "AlSi10Mg", "PA12-CF-SLS"],
      "rapid_prototyping":       ["PLA", "Resin-Standard", "PA12-MJF"],
      "functional_prototype":    ["PETG", "PA12-SLS", "PA12-MJF", "AlSi10Mg"]
    },
    "by_process_availability": {
      "desktop_FDM_easy":        ["PLA", "PETG", "TPU-FDM"],
      "desktop_FDM_advanced":    ["ABS", "ASA", "PA12-FDM", "PC"],
      "industrial_FDM":          ["PEEK-FDM", "CF-short-FDM", "Onyx-ContinuousFiber"],
      "desktop_resin":           ["Resin-Standard", "Resin-Flexible"],
      "professional_resin":      ["Resin-HighTemp", "Resin-Dental-Medical"],
      "sls_service_bureau":      ["PA12-SLS", "PA11-SLS", "PA12-CF-SLS", "TPU-SLS"],
      "mjf_service_bureau":      ["PA12-MJF"],
      "metal_service_bureau":    ["AlSi10Mg", "Ti-6Al-4V", "316L", "17-4PH", "IN625", "IN718", "CoCr"],
      "specialized_only":        ["Scalmalloy", "Cu-pure", "Resin-Ceramic"]
    }
  }
}