Researchers Developed New Reactive Polymer for 3D Printing

BlueSky Polymers, Insight Polymers, and ALM created a material to overcome high melt viscosity in SLS printing.

Updated on Oct. 6, 2026 in Materials Science

Intricate, complex geometric lattice structure made of granular white polymer powder inside a 3D printing build chamber. — BlueSky Polymers, Insight Polymers, and ALM have collaborated to develop a reactive polyetherimide called xPEI to improve 3D printing for complex industrial parts. AI Illustration. Upload story photo >

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BlueSky Polymers, Insight Polymers, and ALM have collaborated to develop a reactive polyetherimide, known as xPEI, for 3D printing. The material enables the creation of complex parts that were previously difficult to manufacture using traditional SLS methods.

Why it matters

High melt viscosity and limited interlayer diffusion have long prevented PEI from being suitable for SLS printing. This new material allows for production of complex geometries that are not feasible through injection molding or subtractive manufacturing.

The xPEI material is based on the Sabic Ultem backbone and requires a controlled thermal cure after printing to increase the glass transition temperature. It is engineered to flow during initial processing and react specifically during heat treatment.

The players

BlueSky Polymers

This startup originated from the University of North Carolina at Chapel Hill.

Insight Polymers

Based in Northeast Tennessee, this organization specializes in polymer production.

ALM

A subsidiary of the EOS Group based in Temple, Texas, the company was founded in 2004.

The details

The material is currently available as a reusable powder for SLS and a filament for FDM. Insight Polymers is producing the material in multi-kilogram quantities as the collaborative team seeks early pilot customers.

ALM was founded in 2004.
Theo Dingemans presented xPEI at the ICAM forum on September 28, 2026.

The Big Picture

This development shifts the trajectory of high-performance polymer additive manufacturing by successfully integrating the Sabic Ultem backbone into SLS workflows. It effectively bridges the gap between traditional injection molding material properties and the flexibility of powder-bed fusion.

This breakthrough could lead to the production of stronger, more durable consumer and industrial plastic components that were previously limited by material constraints. Increased adoption of xPEI may eventually lower production costs for high-performance plastic parts by enabling additive manufacturing at scale.

The takeaway

Advancements in polymer chemistry are essential to expanding the capabilities of 3D printing beyond prototyping and into final part production. Companies looking to implement these materials should focus on the post-processing requirements for thermal curing.