Different materials used in 3d printing

What Materials Are Used in the 3D Printing Process?

The materials used for 3D printing are as diverse as the products that result from the process. As such, 3D printing is flexible enough to allow manufacturers to determine the shape, texture and strength of a product. Best of all, these qualities can be achieved with far fewer steps than what is typically required in traditional means of production. Moreover, these products can be made with various types of 3D printing materials.

In order for a 3D print to be realized in the form of a finished product, a detailed image of the design in question must first be submitted to the printer. The details are rendered in standard triangle language (STL), which conveys the intricacies and dimensions of a given design and allows a computerized 3D printer to see a design from all sides and angles.

Basically, an STL design is the equivalent of multiple flat designs in one computerized file.

The industry for 3D printing is expected to surpass the 10-figure mark in the near future and plastic is set to be the main material to drive this market. As concluded recently in a SmarTech Markets Publishing study, the market for 3D printing is likely to exceed $1.4 billion before 2020. With an ongoing market expansion, the industry has sought new ways to yield plastics, including the use of organic ingredients like soybean oil and corn. Consequently, plastics are set to become the most environmentally friendly option in 3D printing.

Plastic

Out of all the raw materials for 3D printing in use today, plastic is the most common. Plastic is one of the most diverse materials for 3D-printed toys and household fixtures. Products made with this technique include desk utensils, vases and action figures. Available in transparent form as well as bright colors — of which red and lime green are particularly popular — plastic filaments are sold on spools and can have either a matte or shiny texture.

With its firmness, flexibility, smoothness and bright range of color options, the appeal of plastic is easy to understand. As a relatively affordable option, plastic is generally light on the pocketbooks of creators and consumers alike.

Plastic products are generally made with FDM printers, in which thermoplastic filaments are melted and molded into shape, layer by layer. The types of plastic used in this process are usually made from one of the following materials:

Polyastic acid (PLA): One of the eco-friendliest options for 3D printers, polyastic acid is sourced from natural products like sugar cane and corn starch and is therefore biodegradable. Available in soft and hard forms, plastics made from polyastic acid are expected to dominate the 3D printing industry in the coming years. Hard PLA is the stronger and therefore more ideal material for a broader range of products.
Acrylonitrile butadiene styrene (ABS): Valued for its strength and safety, ABS is a popular option for home-based 3D printers. Alternately referred to as “LEGO plastic,” the material consists of pasta-like filaments that give ABS its firmness and flexibility. ABS is available in various colors that make the material suitable for products like stickers and toys. Increasingly popular among craftspeople, ABC is also used to make jewelry and vases.
Polyvinyl Alcohol Plastic (PVA): Used in low-end home printers, PVA is a suitable plastic for support materials of the dissolvable variety. Though not suitable for products that require high strength, PVA can be a low-cost option for temporary-use items.
Polycarbonate (PC): Less frequently used than the aforementioned plastic types, polycarbonate only works in 3D printers that feature nozzle designs and that operate at high temperatures. Among other things, polycarbonate is used to make low-cost plastic fasteners and molding trays.

Plastic items made in 3D printers come in a variety of shapes and consistencies, from flat and round to grooved and meshed. A quick search of Google images will show a novel range of 3D-printed plastic products such as mesh bracelets, cog wheels and Incredible Hulk action figures. For the home craftsperson, polycarbonate spools can now be purchased in bright colors at most supply stores.

Powders

Today’s more state-of-the-art 3D printers use powdered materials to construct products. Inside the printer, the powder is melted and distributed in layers until the desired thickness, texture and patterns are made. The powders can come from various sources and materials, but the most common are:

Polyamide (Nylon): With its strength and flexibility, polyamide allows for high levels of detail on a 3D-printed product. The material is especially suited for joining pieces and interlocking parts in a 3D-printed model. Polyamide is used to print everything from fasteners and handles to toy cars and figures.
Alumide: Comprised of a mix of polyamide and gray aluminum, alumide powder makes for some of the strongest 3D-printed models. Recognized by its grainy and sandy appearance, the powder is reliable for industrial models and prototypes.

In powder form, materials like steel, copper and other types of metal are easier to transport and mold into desired shapes. As with the various types of plastic used in 3D printing, metal powder must be heated to the point where it can be distributed layer-by-layer to form a completed shape.

Resins

One of the more limiting and therefore less-used materials in 3D printing is resin. Compared to other 3D-applicable materials, resin offers limited flexibility and strength. Made of liquid polymer, resin reaches its end state with exposure to UV light. Resin is generally found in black, white and transparent varieties, but certain printed items have also been produced in orange, red, blue and green.

The material comes in the following three categories:

High-detail resins: Generally used for small models that require intricate detail. For example, four-inch figurines with complex wardrobe and facial details are often printed with this grade of resin.
Paintable resin: Sometimes used in smooth-surface 3D prints, resins in this class are noted for their aesthetic appeal. Figurines with rendered facial details, such as fairies, are often made of paintable resin.
Transparent resin: This is the strongest class of resin and therefore the most suitable for a range of 3D-printed products. Often used for models that must be smother to the touch and transparent in appearance.

Transparent resins of clear and colored varieties are used to make figurines, chess pieces, rings and small household accessories and fixtures.

Metal

The second-most-popular material in the industry of 3D printing is metal, which is used through a process known as direct metal laser sintering or DMLS. This technique has already been embraced by manufacturers of air-travel equipment who have used metal 3D printing to speed up and simplify the construction of component parts.

DMLS printers have also caught on with makers of jewelry products, which can be produced much faster and in larger quantities — all without the long hours of painstakingly detailed work — with 3D printing.

Metal can produce a stronger and arguably more diverse array of everyday items. Jewelers have used steel and copper to produce engraved bracelets on 3D printers. One of the main advantages of this process is that the engraving work is handled by the printer. As such, bracelets can be finished by the box-load in just a few mechanically programmed steps that do not involve the hands-on labor that engraving work once required.

The technology for metal-based 3D printing is also opening doors for machine manufacturers to ultimately use DMLS to produce at speeds and volumes that would be impossible with current assembly equipment. Supporters of these developments believe 3D printing would allow machine-makers to produce metal parts with strength superior to conventional parts that consist of refined metals.

In the meantime, the use of 3D parts is taking flight in the aerospace industry. In what has been the most ambitious push of its kind, GE Aviation plans to print engine injectors at an annual rate of 35,000 units by 2020.

The range of metals that are applicable to the DMLS technique is just as diverse as the various 3D printer plastic types:

Stainless-steel: Ideal for printing out utensils, cookware and other items that could ultimately come into contact with water.
Bronze: Can be used to make vases and other fixtures.
Gold: Ideal for printed rings, earrings, bracelets and necklaces.
Nickel: Suitable for the printing of coins.
Aluminum: Ideal for thin metal objects.
Titanium: The preferred choice for strong, solid fixtures.

In the printing process, metal is utilized in dust form. The metal dust is fired to attain its hardness. This allows printers to bypass casting and make direct use of metal dust in the formation of metal parts. Once the printing has completed, these parts can then be electro-polished and released to the market.

Metal dust is most often used to print prototypes of metal instruments, but it has also been used to produce finished, marketable products such as jewelry. Powderized metal has even been used to make medical devices.

When metal dust is used for 3D printing, the process allows for a reduced number of parts in the finished product. For example, 3D printers have produced rocket injectors that consist of just two parts, whereas a similar device welded in the traditional manner will typically consist of more than 100 individual pieces.

Carbon Fiber

Composites such as carbon fiber are used in 3D printers as a top-coat over plastic materials. The purpose is to make the plastic stronger. The combination of carbon fiber over plastic has been used in the 3D printing industry as a fast, convenient alternative to metal. In the future, 3D carbon fiber printing is expected to replace the much slower process of carbon-fiber layup.

With the use of conductive carbomorph, manufacturers can reduce the number of steps required to assemble electromechanical devices.

Graphite and Graphene

Graphene has become a popular choice for 3D printing because of its strength and conductivity. The material is ideal for device parts that need to be flexible, such as touchscreens. Graphene is also used for solar panels and building parts. Proponents of the graphene option claim it is one of the most flexible of 3D-applicable materials.

The use of graphene in printing received its largest boost through a partnership between the 3D Group and Kibaran Resources, an Australian mining company. The pure carbon, which was first discovered in 2004, has proven to be the most electrically conductive material in laboratory tests. Graphene is light yet strong, which makes it the suitable material for a range of products.

Nitinol

As a common material in medical implants, nitinol is valued in the 3D printing world for its super-elasticity. Made from a mixture of nickel and titanium, nitinol can bend to considerable degrees without breaking. Even if folded in half, the material can be restored to its original shape. As such, nitinol is one of the strongest materials with flexible qualities. For the production of medical products, nitinol allows printers to accomplish things that would otherwise be impossible.

Paper

Designs can be printed on paper with 3D technology to achieve a far more realistic prototype than a flat illustration. When a design is presented for approval, the 3D-printed model allows the presenter to convey the essence of the design with greater detail and accuracy. This makes the presentation far more compelling, as it gives a more vivid sense of the engineering realities should the design be taken to fruition.

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Guide to 3D Printing Materials: Types, Applications, and Properties

3D printing empowers you to prototype and manufacture parts for a wide range of applications quickly and cost-effectively. But choosing the right 3D printing process is just one side of the coin. Ultimately, it'll be largely up to the materials to enable you to create parts with the desired mechanical properties, functional characteristics, or looks.

This comprehensive guide to 3D printing materials showcases the most popular plastic and metal 3D printing materials available, compares their properties, applications, and describes a framework that you can use to choose the right one for your project.

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There are dozens of plastic materials available for 3D printing, each with its unique qualities that make it best suited to specific use cases. To simplify the process of finding the material best suited for a given part or product, let’s first look at the main types of plastics and the different 3D printing processes.

There are the two main types of plastics:

Thermoplastics are the most commonly used type of plastic. The main feature that sets them apart from thermosets is their ability to go through numerous melt and solidification cycles. Thermoplastics can be heated and formed into the desired shape. The process is reversible, as no chemical bonding takes place, which makes recycling or melting and reusing thermoplastics feasible. A common analogy for thermoplastics is butter, which can be melted, re-solidify, and melted again. With each melting cycle, the properties change slightly.
Thermosetting plastics (also referred to as thermosets) remain in a permanent solid state after curing. Polymers in thermosetting materials cross-link during a curing process that is induced by heat, light, or suitable radiation. Thermosetting plastics decompose when heated rather than melting, and will not reform upon cooling. Recycling thermosets or returning the material back into its base ingredients is not possible. A thermosetting material is like cake batter, once baked into a cake, it cannot be melted back into batter again.

The three most established plastic 3D printing processes today are the following:

Fused deposition modeling (FDM) 3D printers melt and extrude thermoplastic filaments, which a printer nozzle deposits layer by layer in the build area.
Stereolithography (SLA) 3D printers use a laser to cure thermosetting liquid resins into hardened plastic in a process called photopolymerization.
Selective laser sintering (SLS) 3D printers use a high-powered laser to fuse small particles of thermoplastic powder.

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Fused deposition modeling (FDM), also known as fused filament fabrication (FFF), is the most widely used form of 3D printing at the consumer level, fueled by the emergence of hobbyist 3D printers.

This technique is well-suited for basic proof-of-concept models, as well as quick and low-cost prototyping of simple parts, such as parts that might typically be machined.

Consumer level FDM has the lowest resolution and accuracy when compared to other plastic 3D printing processes and is not the best option for printing complex designs or parts with intricate features. Higher-quality finishes may be obtained through chemical and mechanical polishing processes. Industrial FDM 3D printers use soluble supports to mitigate some of these issues and offer a wider range of engineering thermoplastics or even composites, but they also come at a steep price.

As the melted filament forms each layer, sometimes voids can remain between layers when they don’t adhere fully. This results in anisotropic parts, which is important to consider when you are designing parts meant to bear load or resist pulling.

FDM 3D printing materials are available in a variety of color options. Various experimental plastic filament blends also exist to create parts with wood- or metal-like surfaces.

The most common FDM 3D printing materials are ABS, PLA, and their various blends. More advanced FDM printers can also print with other specialized materials that offer properties like higher heat resistance, impact resistance, chemical resistance, and rigidity.

Material	Features	Applications
ABS (acrylonitrile butadiene styrene)	Tough and durable Heat and impact resistant Requires a heated bed to print Requires ventilation	Functional prototypes
PLA (polylactic acid)	The easiest FDM materials to print Rigid, strong, but brittle Less resistant to heat and chemicals Biodegradable Odorless	Concept models Looks-like prototypes
PETG (polyethylene terephthalate glycol)	Compatible with lower printing temperatures for faster production Humidity and chemical resistant High transparency Can be food safe	Waterproof applications Snap-fit components
Nylon	Strong, durable, and lightweight Tough and partially flexible Heat and impact resistant Very complex to print on FDM	Functional prototypes Wear resistant parts
TPU (thermoplastic polyurethane)	Flexible and stretchable Impact resistant Excellent vibration dampening	Flexible prototypes
PVA (polyvinyl alcohol)	Soluble support material Dissolves in water	Support material
HIPS (high impact polystyrene)	Soluble support material most commonly used with ABS Dissolves in chemical limonene	Support material
Composites (carbon fiber, kevlar, fiberglass)	Rigid, strong, or extremely tough Compatibility limited to some expensive industrial FDM 3D printers	Functional prototypes Jigs, fixtures, and tooling

Stereolithography was the world’s first 3D printing technology, invented in the 1980s, and is still one of the most popular technologies for professionals.

SLA parts have the highest resolution and accuracy, the clearest details, and the smoothest surface finish of all plastic 3D printing technologies. Resin 3D printing is a great option for highly detailed prototypes requiring tight tolerances and smooth surfaces, such as molds, patterns, and functional parts. SLA parts can also be highly polished and/or painted after printing, resulting in client-ready parts with high-detailed finishes.

Parts printed using SLA 3D printing are generally isotropic—their strength is more or less consistent regardless of orientation because chemical bonds happen between each layer. This results in parts with predictable mechanical performance critical for applications like jigs and fixtures, end-use parts, and functional prototyping.

SLA offers the widest range of material options for plastic 3D printing.

SLA 3D printing is highly versatile, offering resin formulations with a wide range of optical, mechanical, and thermal properties to match those of standard, engineering, and industrial thermoplastics.

Formlabs Materials	Features	Applications
Standard Resins	High resolution Smooth, matte surface finish	Concept models Looks-like prototypes
Clear Resin	The only truly clear material for plastic 3D printing Polishes to near optical transparency	Parts requiring optical transparency Millifluidics
Draft Resin	One of the fastest materials for 3D printing 4x faster than standard resins, up to 10x faster than FDM	Initial Prototypes Rapid Iterations
Tough and Durable Resins	Strong, robust, functional, and dynamic materials Can handle compression, stretching, bending, and impacts without breaking Various materials with properties similar to ABS or PE	Housings and enclosures Jigs and fixtures Connectors Wear-and-tear prototypes
Rigid Resins	Highly filled, strong and stiff materials that resist bending Thermally and chemically resistant Dimensionally stable under load	Jigs, fixtures, and tooling Turbines and fan blades Fluid and airflow components Electrical casings and automotive housings
Polyurethane Resins	Excellent long-term durability UV, temperature, and humidity stable Flame retardancy, sterilizability, and chemical and abrasion resistance	High performance automotive, aerospace, and machinery components Robust and rugged end-use parts Tough, longer-lasting functional prototypes
High Temp Resin	High temperature resistance High precision	Hot air, gas, and fluid flow Heat resistant mounts, housings, and fixtures Molds and inserts
Flexible and Elastic Resins	Flexibility of rubber, TPU, or silicone Can withstand bending, flexing, and compression Holds up to repeated cycles without tearing	Consumer goods prototyping Compliant features for robotics Medical devices and anatomical models Special effects props and models
Medical and dental resins	A wide range of biocompatible resins for producing medical and dental appliances	Dental and medical appliances, including surgical guides, dentures, and prosthetics
Jewelry resins	Materials for investment casting and vulcanized rubber molding Easy to cast, with intricate details and strong shape retention	Try-on pieces Masters for reusable molds Custom jewelry
ESD Resin	ESD-safe material to improve electronics manufacturing workflows	Tooling & fixturing for electronics manufacturing Anti-static prototypes and end-use components Custom trays for component handling and storage
Ceramic Resin	Stone-like finish Can be fired to create a fully ceramic piece	Engineering research Art and design pieces

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Selective laser sintering (SLS) 3D printing is trusted by engineers and manufacturers across different industries for its ability to produce strong, functional parts. Low cost per part, high productivity, and established materials make the technology ideal for a range of applications from rapid prototyping to small-batch, bridge, or custom manufacturing.

As the unfused powder supports the part during printing, there’s no need for dedicated support structures. This makes SLS ideal for complex geometries, including interior features, undercuts, thin walls, and negative features.

Just like SLA, SLS parts are also generally more isotropic than FDM parts. SLS parts have a slightly rough surface finish due to the powder particles, but almost no visible layer lines.

SLS 3D printing materials are ideal for a range of functional applications, from engineering consumer products to manufacturing and healthcare.

The material selection for SLS is limited compared to FDM and SLA, but the available materials have excellent mechanical characteristics, with strength resembling injection-molded parts. The most common material for selective laser sintering is nylon, a popular engineering thermoplastic with excellent mechanical properties. Nylon is lightweight, strong, and flexible, as well as stable against impact, chemicals, heat, UV light, water, and dirt.

Material	Description	Applications
Nylon 12	Strong, stiff, sturdy, and durable Impact-resistant and can endure repeated wear and tear Resistant to UV, light, heat, moisture, solvents, temperature, and water	Functional prototyping End-use parts Medical devices
Nylon 11	Similar properties to Nylon 12, but with a higher elasticity, elongation at break, and impact resistance, but lower stiffness	Functional prototyping End-use parts Medical devices
TPU	Flexible, elastic, and rubbery Resilient to deformation High UV stability Great shock absorption	Functional prototyping Flexible, rubber-like end-use parts Medical devices
Nylon composites	Nylon materials reinforced with glass, aluminum, or carbon fiber for added strength and rigidity	Functional prototyping Structural end-use parts

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Different 3D printing materials and processes have their own strengths and weaknesses that define their suitability for different applications. The following table provides a high level summary of some key characteristics and considerations.

	FDM	SLA	SLS
Pros	Low-cost consumer machines and materials available	Great value High accuracy Smooth surface finish Range of functional materials	Strong functional parts Design freedom No need for support structures
Cons	Low accuracy Low details Limited design compatibility High cost industrial machines if accuracy and high performance materials are needed	Sensitive to long exposure to UV light	More expensive hardware Limited material options
Applications	Low-cost rapid prototyping Basic proof-of-concept models Select end-use parts with high-end industrial machines and materials	Functional prototyping Patterns, molds, and tooling Dental applications Jewelry prototyping and casting Models and props	Functional prototyping Short-run, bridge, or custom manufacturing
Materials	Standard thermoplastics, such as ABS, PLA, and their various blends on consumer level machines. High performance composites on high cost industrial machines	Varieties of resin (thermosetting plastics). Standard, engineering (ABS-like, PP-like, flexible, heat-resistant), castable, dental, and medical (biocompatible).	Engineering thermoplastics. Nylon 11, Nylon 12, and their composites, thermoplastic elastomers such as TPU.

Beyond plastics, there are multiple 3D printing processes available for metal 3D printing.

Metal FDM

Metal FDM printers work similarly to traditional FDM printers, but use extrude metal rods held together by polymer binders. The finished “green” parts are then sintered in a furnace to remove the binder.

SLM and DMLS printers work similarly to SLS printers, but instead of fusing polymer powders, they fuse metal powder particles together layer by layer using a laser. SLM and DMLS 3D printers can create strong, accurate, and complex metal products, making this process ideal for aerospace, automotive, and medical applications.

Titanium is lightweight and has excellent mechanical characteristics. It is strong, hard and highly resistant to heat, oxidation, and acid.
Stainless steel has high strength, high ductility, and is resistant to corrosion.
Aluminum is a lightweight, durable, strong, and has good thermal properties.
Tool steel is a hard, scratch-resistant material that you can use to print end-use tools and other high-strength parts..
Nickel alloys have high tensile, creep and rupture strength and are heat and corrosion resistant.

Compared to plastic 3D printing technologies, metal 3D printing is substantially more costly and complex, limiting its accessibility to most businesses.

Alternatively, SLA 3D printing is well-suited for casting workflows that produce metal parts at a lower cost, with greater design freedom, and in less time than traditional methods.

Another alternative is electroplating SLA parts, which involves coating a plastic material in a layer of metal via electrolysis. This combines some of the best qualities of metal—strength, electrical conductivity, and resistance to corrosion and abrasion—with the specific properties of the primary (usually plastic) material.

Plastic 3D printing is well-suited to create patterns that can be cast to produce metal parts.

With all these materials and 3D printing options available, how can you make the right selection?

Here’s our three-step framework to choose the right 3D printing material for your application.

Plastics used for 3D printing have different chemical, optical, mechanical, and thermal characteristics that determine how the 3D printed parts will perform. As the intended use approaches real-world usage, performance requirements increase accordingly.

Requirement	Description	Recommendation
Low performance	For form and fit prototyping, conceptual modeling, and research and development, printed parts only need to meet low technical performance requirements. Example: A form prototype of a soup ladle for ergonomic testing. No functional performance requirements needed besides surface finish.	FDM: PLA SLA: Standard Resins, Clear Resin (transparent part), Draft Resin (fast printing)
Moderate performance	For validation or pre-production uses, printed parts must behave as closely to final production parts as possible for functional testing but do not have strict lifetime requirements. Example: A housing for electronic components to protect against sudden impact. Performance requirements include ability to absorb impact, housing needs to snap together and hold its shape.	FDM: ABS SLA: Engineering Resins SLS: Nylon 11, Nylon 12, TPU
High performance	For end-use parts, final 3D printed production parts must stand up to significant wear for a specific time period, whether that’s one day, one week, or several years. Example: Shoe outsoles. Performance requirements include strict lifetime testing with cyclic loading and unloading, color fastness over periods of years, amongst others like tear resistance.	FDM: Composites SLA: Engineering, Medical, Dental, or Jewelry Resins SLS: Nylon 11, Nylon 12, TPU, nylon composites

Once you’ve identified the performance requirements for your product, the next step is translating them into material requirements—the properties of a material that will satisfy those performance needs. You’ll typically find these metrics on a material’s data sheet.

Requirement	Description	Recommendation
Tensile strength	Resistance of a material to breaking under tension. High tensile strength is important for structural, load bearing, mechanical, or statical parts.	FDM: PLA SLA: Clear Resin, Rigid Resins SLS: Nylon 12, nylon composites
Flexural modulus	Resistance of a material to bending under load. Good indicator for either the stiffness (high modulus) or the flexibility (low modulus) of a material.	FDM: PLA (high), ABS (medium) SLA: Rigid Resins (high), Tough and Durable Resins (medium), Flexible and Elastic Resins (low) SLS: nylon composites (high), Nylon 12 (medium)
Elongation	Resistance of a material to breaking when stretched. Helps you compare flexible materials based on how much they can stretch. Also indicates if a material will deform first, or break suddenly.	FDM: ABS (medium), TPU (high) SLA: Tough and Durable Resins (medium), Polyurethane Resins (medium), Flexible and Elastic Resins (high) SLS: Nylon 12 (medium), Nylon 11 (medium), TPU (high)
Impact strength	Ability of a material to absorb shock and impact energy without breaking. Indicates toughness and durability, helps you figure out how easily a material will break when dropped on the ground or crashed into another object.	FDM: ABS, Nylon SLA: Tough 2000 Resin, Tough 1500 Resin, Grey Pro Resin, Durable Resin, Polyurethane Resins SLS: Nylon 12, Nylon 11, nylon composites
Heat deflection temperature	Temperature at which a sample deforms under a specified load. Indicates if a material is suitable for high temperature applications.	SLA: High Temp Resin, Rigid Resins SLS: Nylon 12, Nylon 11, nylon composites
Hardness (durometer)	Resistance of a material to surface deformation. Helps you identify the right “softness” for soft plastics, like rubber and elastomers for certain applications.	FDM: TPU SLA: Flexible Resin, Elastic Resin SLS: TPU
Tear strength	Resistance of a material to growth of cuts under tension. Important to assess the durability and the resistance to tearing of soft plastics and flexible materials, such as rubber.	FDM: TPU SLA: Flexible Resin, Elastic Resin, Durable Resin SLS: Nylon 11, TPU
Creep	Creep is the tendency of a material to deform permanently under the influence of constant stress: tensile, compressive, shear, or flexural. Low creep indicates longevity for hard plastics and is crucial for structural parts.	FDM: ABS SLA: Polyurethane Resins, Rigid Resins SLS: Nylon 12, Nylon 11, nylon composites
Compression set	Permanent deformation after material has been compressed. Important for soft plastics and elastic applications, tells you if a material will return to its original shape after the load is removed.	FDM: TPU SLA: Flexible Resin, Elastic Resin SLS: TPU

For even more details on material properties, read our guide to about the most common mechanical and thermal properties.

Once you translate performance requirements to material requirements, you’ll most likely end up with a single material or a smaller group of materials that could be suitable for your application.

If there are multiple materials that fulfil your basic requirements, you can then look at a wider range of desired characteristics and consider the pros, cons, and trade-offs of the given materials and processes to make the final choice.

Try our interactive material wizard to find materials based on your application and the properties you care the most about from our growing library of materials. Do you have specific questions about 3D printing materials? Contact our experts.

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types, applications and features

3D printing enables rapid and cost-effective prototyping and production of models for a wide range of applications. But choosing the right 3D printing technology is only one side of the coin. Ultimately, the ability to create models with the required mechanical properties, functional characteristics or appearance will depend on the materials.

This comprehensive guide provides information on the most popular plastic and metal 3D printing materials available, compares their properties and applications, and provides guidance on how to select the most suitable material for your project.

Interactive Material

Need help choosing your 3D printing material? Our new interactive materials wizard will help you select the right material from our growing range of polymers, based on your intended application and the properties that matter most to you.

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Dozens of plastic materials are available for 3D printing. Each of them has unique properties suitable for specific applications. To make it easier to find the best material for a particular model or product, let's first look at the main types of plastics and the various 3D printing processes.

There are two main types of plastics:

thermoplastics are the most common type of plastics. The main feature that distinguishes them from thermosetting plastics is their ability to withstand multiple melting and solidification cycles. Thermoplastics can be heated and shaped into desired shapes. This process is reversible because no chemical bond is formed. As a result, they can be recycled or melted down and reused. Thermoplastics can be compared to butter: it melts and hardens many times. With each melting cycle, the properties of thermoplastics change slightly.
thermoset plastics (also called thermosets) remain permanently solid after polymerization. The polymers in thermosetting plastics are crosslinked during the polymerization process, which is induced by heat, light, or appropriate radiation. Thermoset plastics decompose when heated, rather than melt. In addition, they do not change their shape when cooled. It is not possible to recycle thermosetting plastics or restore the material to its original state. Thermosetting is like pie dough: once baked, the pie cannot be melted back into dough.

The three most common plastic 3D printing processes today are:

Fused Deposition Modeling (FDM) 3D printers melt and extrude thermoplastic filaments, which the printer's nozzle deposits layer by layer on the work area.
The Stereolithography (SLA) 3D Printer uses a laser to photopolymerize thermoset liquid polymers into a hardened plastic.
The Selective Laser Sintering (SLS) 3D Printer is equipped with a high power laser to sinter fine particles of thermoplastic powder.

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Fused fusion modeling (FDM), also known as fused filament manufacturing (FFF), is the most common form of consumer grade 3D printing, fueled by the rise of hobbyist 3D printers.

This method is well suited for making basic experimental models, as well as for quickly and inexpensively prototyping simple products, such as parts that are usually machined.

Consumer grade FDM has the lowest resolution and accuracy of any other plastic 3D printing process, making it unsuitable for printing complex designs or models with intricate features. It is possible to improve the surface quality of models printed using this technology using chemical and mechanical polishing processes. FDM-based industrial 3D printers, which offer a wider range of engineering thermoplastics, can solve these problems, but are also much more expensive.

Each layer is formed with a thermoplastic thread. Sometimes, if the layers are not completely adjacent to each other, there may be voids between them. As a result, anisotropic models are obtained, which is important to consider when designing products that must withstand load and be resistant to tension.

FDM 3D printing materials are available in a variety of colors. There are also various experimental mixtures of thermoplastic threads designed to create models with a surface that mimics wood or metal.

The most common materials for 3D printing in FDM technology are ABS (acrylonitrile butadiene styrene), PLA (polylactic acid) and various mixtures of these polymers. More advanced FDM printers can also print on other materials with different properties, such as increased temperature and chemical resistance, impact resistance, and rigidity.

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Material	Features	Methods of use
ABS (acrylonitril-butadien-styrol)	Strong and durable Thermal and impact-resistant need for a heated printing platform		Easiest media to print with FDM technology Strong, tough but brittle Less resistant to temperature and chemicals The biodegradable does not have a smell of	Conceptual models Realistic prototypes
PETG (polyethylenertalatlatglycol)	is compatible with low printing temperatures .	Waterproof application Clip-on components
nylon	Hard, durable and light Strong and partially flexible heat -resistant and impact -resistant Complex for printing using FDM	Functional Prototypes Basement models
TPU (thermal polyurate)	Flexible Prototypes
PVA (polyvinyl alcohol)	Soluble support structure material The material for supporting structures
impact -resistant polystyrene	The material for creating soluble supporting structures, the most commonly used with ABS	Material for supporting structures
Composit materials (carbon, composite composite materials are dissolved in water. Kevlar, fiber optic)	Strong, tough and incredibly hard Only compatible with some expensive industrial 3D printers based on FDM technology	Functional prototypes Clamping fixtures, fixtures, tooling

Invented in the 1980s, stereolithography is the world's first 3D printing technology and is still one of the most popular among professionals today.

Models printed with stereolithography printers have the highest resolution and accuracy, the sharpest detail and the smoothest surface of any other plastic 3D printing technology. Resin 3D printing is a great option for producing highly detailed prototypes that require tight tolerances and smooth surfaces such as molds, templates, and functional models. Models printed using SLA technology can be easily polished and/or painted after printing, resulting in highly detailed finished products.

Models printed on SLA 3D printers are generally isotropic: their strength is more or less constant and independent of orientation, since chemical bonds occur between each layer. This results in models with predictable mechanical characteristics critical for applications such as fasteners, fixtures, finished products, and functional prototypes.

Stereolithography supports a wide range of plastic 3D printing materials.

SLA 3D printing is versatile and provides a wide range of optical, mechanical and thermal properties that match those of standard, engineering and industrial thermoplastics.

jewelry resins

Materials of FORMLABS	Characteristics	Methods of use
Standard polymers	High resolution Smote, matte surface	Conceptual models 958 Conceptual models	Conceptual Models Realistic prototypes
Clear Resin	The only truly transparent material for 3D printing from plastics can be polished to almost full optical transparency	models, which should be optically transparent
DRAFT REDI	One of the fastest 3D printing materials Prints 4x faster than standard resins and 10x faster than FDM	Initial prototypes Rapid iterations
Tough Resin and Durable Resin	Materials that are tough, strong, functional and dynamic Able to withstand compression, tension, bending and impact without breaking Various materials with properties similar to ABS	Enclosures and Enclosures Clamps and Mounting Devices Connectors Wear Prototypes
Rigid Resins	Highly filled, stiff and strong material, resistant to bending Resistant to temperature and chemicals Maintains dimension under load	Clamping and holding fixtures, tooling Turbines and fan blades Fluid/air components Electrical enclosures and housings used in the automotive industry
High Temp Resin	High temperature resistant High Precision	Hot Air, Gas, and Liquid Components Heat Resistant Fasteners, Housings, and Fixtures Molds and Inserts
Flexible Resin and Elastic Resin	Flexibility of Rubber, TPU, or Silicone compression Withstand many successive cycles without wear	Consumer product prototypes Foldable structures for robotics Medical devices and anatomy models Props and models for special effects
Medical and dental resins	A wide range of biocompatible resins for the manufacture of medical and dental products	Dental and medical products, including surgical templates, dentures and prosthetic limbs
Lost Wax and Vulcanized Rubber Casting Materials Easy to cast, allows for intricate designs and retains shape well	Products for trying on Models for reusable press forms Jewelry to order
Ceramic Resin	Surface System, similar to the Firing Personal Product, the possibility of firing for creating a real ceramic product	Technical survival Unique articles 908

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Selective laser sintering (SLS) 3D printing is a technology trusted by engineers and manufacturers across industries to create durable and functional models. With its low model cost, high performance, and use of common materials, this technology is well suited for a wide range of applications, from rapid prototyping to low-volume production, limited trial runs, or custom-made products.

The green powder supports the model during printing and eliminates the need for special support structures. As a result, SLS is ideal for complex geometries, including internal features, undercuts, thin walls, and negative draft features.

Like stereolithography, SLS produces more isotropic models than FDM models. Models created with SLS technology have a slightly rough surface due to powder particles, but have almost no visible layer lines.

SLS 3D printing materials are ideal for a range of functional applications, from consumer product design to manufacturing and healthcare applications.

Compared to FDM and SLA technologies, SLS technology allows the use of a limited number of materials. However, the available materials have excellent mechanical properties. They have strength comparable to die-cast models. The most common selective laser sintering material is nylon, a popular engineering thermoplastic with excellent mechanical properties. Nylon is light, strong and flexible, resistant to impact, heat, chemicals, UV radiation, water and dirt.

Material	Description	Methods of use
Nylon 12 Powder	Strong, hard and durable Siberian, Solp. water	Functional prototypes End use products Medical devices
Nylon 11 Powder	Similar properties to Nylon 12 Powder. Possesses greater elasticity, elongation at break and impact resistance, but less rigidity	Functional prototypes Products for the final use of Medical devices
TPU	Flexible, elastic, elastic resistant to deformation High resistance to ultraviolet Excellent damping capacity	. end use Medical devices
Nylon composites	Nylon materials reinforced with glass, aluminum or fiberglass for greater strength and rigidity	Functional Prototypes Structural End-Use Products

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Different 3D printing materials and processes have their own advantages and disadvantages that make them suitable for different scenarios. The following table provides a brief overview of some of the main features and factors to consider. Disadvantages Poor accuracy
Poor detail
Limited conformance to design design
High cost of industrial devices if precision and high performance materials are required Susceptibility to prolonged UV exposure More expensive supply of materials More expensive2 Applications Inexpensive Rapid Prototyping
Basic experimental models
Production of special end-use products using professional industrial devices and materials Functional prototypes
Templates, molds and tooling
Dental products
Prototypes and molds for casting jewelry
Props and models Functional prototypes
Small-scale production, production of limited trial runs, creation of products to order Materials Standard thermoplastics such as ABS, PLA and their various blends on consumer grade devices. High performance composite materials on high value industrial applications Various polymers (thermosetting plastics). Standard, engineering (similar to ABS and PP, flexible, heat resistant), molding, dental and medical (biocompatible). Engineering thermoplastics. Nylon 11 Powder, Nylon 12 Powder and their composite materials, thermoplastic elastomers such as TPU.

There are several 3D printing processes not only from plastics, but also from metals.

Metal FDM printers are similar in design to traditional FDM printers, but use extruded metal rods held in place by a resin binder. The finished models are in an intermediate state and then sintered in an oven to remove the binder.

SLM and DMLS printers are similar to SLS printers, but instead of polymer powders, they fuse metal powder particles layer by layer using a laser. 3D printers based on SLM and DMLS technologies can create strong, precise and complex metal products, making this process ideal for the aerospace, automotive and medical industries.

Titanium is a light metal with excellent mechanical properties. It is strong, hard and highly resistant to heat, oxidation and acids.
stainless steel has high strength, ductility and corrosion resistance.
aluminum is a lightweight, durable, strong metal with good thermal properties.
Tool Steel is a hard, scratch-resistant material that can be used to print end-use tools and other high-strength products.
nickel alloys have high tensile, creep and tensile strength, as well as heat and corrosion resistance.

Compared to plastic 3D printing technologies, metal 3D printing is much more expensive and difficult, and therefore beyond the reach of most companies.

As an alternative to casting workflows that produce metal models cheaper and faster than traditional methods and provide greater design freedom, SLA 3D printing is well suited.

Another alternative is galvanization of SLA printed models. It involves applying a layer of metal to plastic using electrolysis. This combines some of the best qualities of metal (strength, electrical conductivity, corrosion and abrasion resistance) with the special properties of the base (usually plastic) material.

Plastic 3D printing is well suited for creating templates that can be cast to produce metal models.

With so many materials and options available for 3D printing, making the right choice can be difficult.

We provide a 3-step process for selecting the right material for 3D printing.

Plastics used for 3D printing have different chemical, optical, mechanical and thermal characteristics that affect the properties of 3D printed models. As you move from the intended use case to the actual operating environment, the performance requirements increase accordingly.

Requirement	Description	Recommendations
Low Efficiency	Example: Prototype mold for a ladle for ergonomic testing. Other than surface quality, there are no performance requirements.	FDM PLA SLA: Standard Resins, Clear Resin (transparency), Draft Resin (fast)
Medium Efficiency	For validation or pre-production use, printed models should have properties as close as possible to those of final production models , for functional testing, but do not meet stringent requirements regarding service life. Example: housing for electronic components to protect against sudden impacts. Functional characteristics include the ability to absorb impact energy. In addition, the body must snap into place and retain its shape.	FDM ABS SLA: Engineering Resins SLS: Nylon 11 Powder, Nylon 12 Powder, TPU
High Efficiency	Final 3D printed models need to be highly stable to achieve end use products to wear and tear over a certain period of time, whether it be a day, a week or several years. Example: shoe soles. Functional features include rigorous cycling and unloading life testing, color fastness over many years, and tear resistance, among other things.	FDM Composites SLA: Engineering, Medical, Dental or Jewelry Resins SLS: Nylon 11 Powder, Nylon 12 Powder, TPU, Nylon Composites

material requirements: material properties that will satisfy these requirements. These indicators are usually given in the technical specifications of the material.

Requirement	Description	Recommendation
Tensile strength	Resistance of material to fracture under tension. High tensile strength is important for structural, load-bearing, mechanical or static models.	FDM PLA SLA: Clear Resin, Rigid Resin SLS: Nylon 12 Powder, Nylon Composites
Flex Modulus	Material resistance to bending under load. Indicates either rigidity (high value) or flexibility (low value) of the material.	FDM PLA (high), ABS (medium) SLA: Rigid Resin (high), Tough Resin and Durable Resin (medium), Flexible Resin and Elastic Resin (low) SLS: Nylon composite materials (high value), Nylon 12 Powder (medium value)
Elongation	Material resistance to tensile failure. Allows you to compare the degree of stretching of flexible materials. It also indicates whether the material is stretched or immediately destroyed.	FDM ABS (medium), TPU (high) SLA: Tough Resin and Durable Resin (medium), Flexible Resin and Elastic Resin (high) SLS: Nylon 12 Powder (medium), Nylon 11 Powder (medium), TPU (high)
Impact strength	The ability of a material to absorb impact and its energy without breaking. Shows toughness and durability. Allows you to determine how easily the material breaks when it falls to the ground or collides with another object.	FDM ABS, Nylon SLA: Tough 2000 Resin, Tough 1500 Resin, Gray Pro Resin, Durable Resin SLS: Nylon 12 Powder, Nylon 11 Powder a certain load. Indicates whether the material is suitable for high temperature applications.	SLA: High Temp Resin, Rigid Resin SLS: Nylon 12 Powder, Nylon composites
Hardness (durometer)	Material resistance to surface deformation. Allows you to determine the right degree of plasticity for soft plastics such as rubber and elastomers for a particular application.	FDM TPU SLA: Flexible Resin, Elastic Resin SLS: TPU
Tear resistance	Material resistance to notching under tension. This indicator is important for evaluating the durability and wear resistance of soft plastics and flexible materials such as rubber.	FDM TPU SLA: Flexible Resin, Elastic Resin, Durable Resin SLS: Nylon 11 Powder, TPU
Creep	Creep is the tendency of a material to permanently deform under the influence of constant stress: tension or bending, compression, shear . Low creep indicates durability of hard plastics and is very important for structural models.	FDM ABS SLA: Rigid Resin SLS: Nylon 12 Powder, Nylon 9 composites0092
Compression set	Irreversible deformation after material compression. An important indicator for soft plastics and applications where flexibility is needed. Indicates whether the material will restore its original shape after the load is removed.	FDM TPU SLA: Flexible Resin, Elastic Resin SLS: TPU

For more information on material properties, see our guide to the most common mechanical and thermal properties.

By converting performance characteristics into material requirements, you can most likely find out which material, or small group of materials, is right for your application.

If several materials meet your basic requirements, a broader range of desired characteristics, as well as the advantages and disadvantages of these materials and processes, can be considered for the final selection.

Use our interactive material wizard. It will help you select the right materials from our growing range of polymers for your application and the properties that matter most to you. Do you have specific questions about 3D printing materials? Contact our experts.

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3D printing materials / Articles

Retrieved
FFF technology has many advantages, including the relative simplicity of the design of printers and the affordability of both devices and consumables. Moreover, the range of materials is perhaps the widest among all available technologies. As a rule, thermoplastics are used for printing, but there are exceptions - composite materials containing various additives, but based, again, on thermoplastics. In this section, we will try to talk about the most widely used materials in more detail, starting with the most popular types.

Polylactide (PLA)

Polylactide is one of the most widely used thermoplastics due to several factors. Let's start with the fact that PLA is known for its environmental friendliness. This material is a lactic acid polymer, which makes PLA a completely biodegradable material. The raw materials for the production of polylactide are corn and sugar cane. At the same time, the environmental friendliness of polylactide causes its fragility. Plastic easily absorbs water and is relatively soft. As a rule, PLA models are not intended for functional use, but serve as designer models, souvenirs and toys. Few practical industrial applications include the production of food packaging, drug containers and surgical sutures, as well as use in bearings that do not carry high mechanical loads (for example, in modeling), which is possible due to the material's excellent slip coefficient.

One of the most important factors for 3D printing applications is the low melting temperature of only 170-180°C, which contributes to relatively low power consumption and the use of inexpensive brass and aluminum nozzles. As a rule, extrusion is carried out at 160-170°C. At the same time, PLA solidifies quite slowly (glass transition temperature is about 50°C), which should be taken into account when choosing a 3D printer. The best option is a device with an open case, a heated work platform (to avoid deformation of large models) and, preferably, additional fans to cool the fresh layers of the model.

PLA has low shrinkage, i.e. loss of volume on cooling, which helps to prevent warping. However, shrinkage has a cumulative effect as the dimensions of printed models increase. In the latter case, the build platform may need to be heated to evenly cool the printed objects.

The cost of PLA is relatively low, which adds to the popularity of this material.

Acrylonitrile butadiene styrene (ABS)

ABS plastic is perhaps the most popular thermoplastic used in 3D printing, but not the most common. This contradiction is explained by certain technical difficulties that arise when printing ABS. The desire of craftsmen to use ABS is determined by the excellent mechanical properties, durability and low cost of this material. In industry, ABS plastic is already widely used: the production of car parts, cases of various devices, containers, souvenirs, various household accessories, etc.

ABS plastic is resistant to moisture, acids and oil, has a fairly high temperature resistance - from 90°C to 110°C. Unfortunately, some types of material are destroyed by direct sunlight, which somewhat limits the application. At the same time, ABS plastic is easy to paint, which allows you to apply protective coatings on non-mechanical elements.

Despite a relatively high glass transition temperature of around 100°C, ABS has a relatively low melting point. Actually, due to the amorphous nature of the material, ABS does not have a melting point, as such, but 180 ° C is considered an acceptable temperature for extrusion, which is on the same level as the above-described PLA. The lower temperature spread between extrusion and glass transition allows ABS to cure faster than PLA.

The main disadvantage of ABS plastic can be considered a high degree of shrinkage during cooling - the material can lose up to 0.8% of its volume. This effect can lead to significant deformations of the model, twisting of the first layers and cracking. To combat these unpleasant phenomena, two main solutions are used. First, heated work platforms are used to help reduce the temperature gradient between the lower and upper layers of the model. Secondly, ABS 3D printers often use closed housings and control of the background temperature of the working chamber. This makes it possible to maintain the temperature of the applied layers at a level just below the glass transition threshold, reducing the degree of shrinkage. Full cooling is carried out after receiving the finished model.

The relatively low stickiness of ABS may require additional bonding aids such as adhesive tape, polyimide film, or applying a solution of ABS in acetone to the platform just prior to printing. For more information on how to avoid warping, see How to Avoid Warping 3D Printed Models.

While ABS does not pose a health risk at room temperature, heating plastic releases acrylonitrile fumes, a poisonous compound that can irritate mucous membranes and cause poisoning. Although the amount of Acrylonitrate produced in small scale printing is negligible, it is recommended that you print in a well ventilated area or use an exhaust hood. It is not recommended to use ABS plastic for the production of food containers and utensils (especially for storing hot food or alcoholic beverages) or toys for small children.

The good solubility of ABS in acetone is very useful, as it allows large models to be produced piece by piece and then glued together, greatly expanding the capabilities of inexpensive desktop printers.

Polyvinyl alcohol (PVA)

Polyvinyl alcohol is a material with unique properties and special applications. The main feature of PVA is its water solubility. 3D printers equipped with dual extruders have the ability to print models with PVA support structures. Upon completion of printing, the supports can be dissolved in water, leaving a finished model that does not require mechanical or chemical roughening. Similarly, PVA can be used to create water-soluble master patterns for molds and molds themselves.

The mechanical properties of PVA are quite interesting. At low humidity, plastic has high tensile strength. With increasing humidity, strength decreases, but elasticity increases. The extrusion temperature is 160-175°C, which allows the use of PVA in printers designed for printing with ABS and PLA plastics.

Since the material easily absorbs moisture, it is recommended to store PVA plastic in dry packaging and, if necessary, dry before use. Drying can be done in a pottery kiln or an ordinary oven. As a rule, drying of standard coils takes 6-8 hours at a temperature of 60-80°C. Exceeding 220°C will cause the plastic to decompose, which should be taken into account when printing.

Nylon

Nylon is attractive due to its high wear resistance and low coefficient of friction. Thus, nylon is often used to coat friction parts, which improves their performance and often allows them to function without lubrication. Following the widespread use of nylon in industry, additive manufacturing has also become interested in the material. Attempts to print with nylon have been made almost since the early days of FDM/FFF technology.

In reality, there are several types of nylon produced by different methods and with slightly different characteristics. The most famous is nylon-66, created by the American company DuPont in 1935. The second most popular option is nylon-6, developed by BASF to circumvent the DuPont patent. These two options are very similar. In terms of 3D printing, the main difference is the melting point: Nylon-6 melts at 220°C, while Nylon-66 melts at 265°C.

Many hobbyists prefer to use commercially available nylon threads such as trimmer wire. The diameter of such materials often corresponds to the diameter of standard FFF materials, which makes their use tempting. At the same time, these products are usually not pure nylon. In the case of trimmer rods, the material consists of nylon and fiberglass for an optimal combination of flexibility and rigidity.

Fiberglass has a high melting point, and therefore printing with such materials is fraught with high nozzle wear and plugging.

Recently there have been attempts to commercially develop nylon-based printing materials specifically for FDM/FFF applications, including Nylon-PA6 and Taulman 680. These grades are extrudable at 230-260°C.

Since nylon readily absorbs moisture, store consumables in vacuum packaging or at least in a container with water-absorbent materials. A sign of excessively damp media will be steam escaping from the nozzle during printing, which is not dangerous, but may degrade the quality of the model.

When printing with nylon, it is not recommended to use a polyimide desktop coating as the two materials fuse together. As a coating, you can use adhesive tape with wax impregnation (masking tape). The use of a heated bed will help reduce the possibility of deformation of the model, similar to printing with ABS plastic. Due to the low coefficient of friction of nylon, extruders with studded feeders should be used.

The nylon layers have excellent adhesion, which minimizes the chance of delamination of models.

Nylon is difficult to bond, making it difficult to print large multi-piece models. Alternatively, fusion of parts is possible.

Since nylon can release toxic fumes when heated, we recommend that you print in a well-ventilated area or use an exhaust fan.

Polycarbonate (PC)

Polycarbonates are attractive due to their high strength and toughness, as well as resistance to high and low temperatures.

The potential health risk of printing is worth noting: the toxic and potentially carcinogenic compound bisphenol A is often used as a raw material. .

The extrusion temperature depends on the printing speed to avoid cracking, but the minimum temperature at 30mm/sec can be considered as 265°C. When printing, the use of polyimide film is recommended for better adhesion to the desktop surface. The high susceptibility of polycarbonate to deformation requires the use of a heated platform and, if possible, a closed housing with heating of the working chamber.

Polycarbonate is highly hygroscopic (easily absorbs moisture), which requires storage in dry conditions to avoid the formation of bubbles in the applied layers. For extended printing in humid climates, even the print spool may need to be stored in a moisture-proof container.

High density polyethylene (HDPE)

Arguably the most common plastic in the world, polyethylene is relatively rare among 3D printed materials. The reason for this is the difficulty in layer-by-layer manufacturing of models.

Polyethylene melts easily (130-145°C) and hardens quickly (100-120°C), as a result of which the applied layers often do not have time to set. In addition, polyethylene is characterized by high shrinkage, which provokes the twisting of the first layers and the deformation of the models as a whole during uneven solidification. Printing with polyethylene requires the use of a heated platform and a working chamber with accurate temperature control to slow down the cooling of the applied layers. In addition, you will need to print at high speed.

Difficulties in use are more than offset by the cheapness and availability of this material. Recently, several devices have been developed for processing plastic waste from HDPE (bottles, food packaging, etc.) into standard filaments for printing on FDM/FFF printers. Examples are FilaBot and RecycleBot. Due to the simplicity of design, RecycleBot devices are often assembled by 3D craftsmen.

Melting polyethylene releases harmful vapors, so it is recommended to print in well-ventilated areas.

Polypropylene (PP, PP)

Polypropylene is a widely used plastic used in the production of packaging materials, dishes, syringes, pipes, etc. The material has a low specific gravity, is non-toxic, has good chemical resistance, is resistant to moisture and wear, and is quite cheap. Among the disadvantages of polypropylene, one can note the vulnerability to temperatures below -5 ° C and to direct sunlight.

The main difficulty in printing with polypropylene is the high shrinkage of the material during cooling - up to 2.4%. For comparison, the shrinkage of the popular but already problematic ABS plastic reaches 0.8%. Although polypropylene adheres well to cold surfaces, it is recommended to print on a heated platform to avoid deformation of models. The minimum recommended extrusion temperature is 220°C.

Polypropylene printing filaments are sold by Orbi-Tech, German RepRap, Qingdao TSD Plastic. Stratasys has developed a polypropylene simulant optimized for 3D printing called Endur.

Polycaprolactone (PCL)

Polycaprolactone (aka Hand Moldable Plastic, Mold-Your-Own Grips, InstaMorph, Shapelock, Friendly Plastic, Polymorph, Polymorphus, Ecoformax) is a biodegradable polyester with an extremely low melting point of about 60°C. In practice, this property creates certain problems in 3D printing, since not all 3D printers can be configured to work at such low temperatures. Heating polycaprolactone to the usual extrusion temperatures (about 200°C) causes a loss of mechanical properties and may lead to breakage of the extruder.

Polycaprolactone is non-toxic, making it suitable for use in the medical industry and biodegradable. When ingested, polycaprolactone breaks down, which makes printing with this material safe. Due to the low melting point, there is no danger of burns when touching fresh models. The high plasticity of the material makes it possible to reuse.

Polycaprolactone is not suitable for creating functional mechanical models due to its viscosity (glass transition temperature is -60°C) and low heat resistance (melting point is 60°C). On the other hand, this material is perfect for the production of mock-ups and food containers.

The material sticks easily to the surface of even a cold working table and is easy to paint.

Polyphenylsulfone (PPSU)

Polyphenylsulfone is a high-strength thermoplastic widely used in the aviation industry. The material has excellent chemical and thermal stability and practically does not burn. Polyphenylsulfone is biologically inert, which makes it possible to use this material for the production of tableware and food containers. Operating temperature range is -50°С - 180°С. Plastic is resistant to solvents and fuels and lubricants.

For all its merits, polyphenylsulfone is rarely used in 3D printing due to its high melting point, reaching 370°C. Such extrusion temperatures are beyond the power of most desktop printers, although printing is theoretically possible using ceramic nozzles. Currently, the only active user of the material is Stratasys, which offers industrial Fortus installations.

Polymethyl methacrylate (Acrylic, plexiglass, acrylic, PMMA)

Polymethyl methacrylate is a well-known organic glass. The material is durable, moisture resistant, environmentally friendly, easy to glue, plastic enough and resistant to direct sunlight.

Unfortunately, acrylic is not suitable for FDM/FFF printing for a number of reasons. Acrylic is poorly stored in the form of spools of thread, as constant mechanical stress leads to the gradual destruction of the material. To avoid bubbles, the print resolution must be high, with a precision almost impossible for home printers. Acrylic's rapid curing requires strict environmental control of the working chamber and high print speeds. Again, the print speeds of FDM/FFF printers are inversely related to print resolution, which exacerbates the problem.

However, attempts are being made to print with acrylic, and some of them are producing relatively positive results. However, when creating sufficiently strong models, it is not yet possible to avoid the formation of bubbles and achieve the usual transparency of the material. At the moment, the best results with acrylic are shown by another printing technology - multi-jet modeling (MJM) from 3D Systems. In this case, a photopolymer version of acrylic is used. Stratasys has also made significant progress using its own photopolymer acrylic simulant VeroClear on Objet Eden printers. It is hoped that the high demand for acrylic will lead to the emergence of composite materials based on polymethyl methacrylate, designed specifically for FDM/FFF printing.

Polyethylene terephthalate (PET, PET)

Polyethylene terephthalate - this complex name hides a material used for the production of plastic bottles and other food and medical containers.

The material has a high chemical resistance to acids, alkalis and organic solvents. The physical properties of PET are also impressive with high wear resistance and tolerance to a wide temperature range from -40°C to 75°C. Among other things, the material is easily machined.

Printing with PET is somewhat problematic due to the relatively high melting point of up to 260°C and significant cooling shrinkage of up to 2%. Using PET as a consumable requires approximately the same conditions as printing with ABS.

Achieving transparency of models requires rapid cooling to pass the glass transition threshold of 70°C - 80°C.

The material has become the focus of attention of 3D craftsmen using used containers as raw materials for home production of 3D printing consumables. Recycling devices such as FilaBot or RecycleBot are used to make threads.

High impact polystyrene (HIPS)

High impact polystyrene is widely used in the industry for various household products, building materials, disposable tableware, toys, medical instruments, etc.

When 3D printed, polystyrene exhibits physical properties very similar to the popular ABS -plastic, which makes this material more and more popular among 3D craftsmen. The most attractive feature of polystyrene is the difference from ABS in terms of chemical properties: polystyrene is quite easily amenable to the organic solvent Limonen. Since Limonene has no effect on ABS plastic, it is possible to use polystyrene as a material for building soluble support structures, which is extremely useful when building complex, interlaced models with internal supports. Compared to the convenient, water-soluble polyvinyl alcohol (PVA) plastic, polystyrene compares favorably with relatively low cost and resistance to humid climates that make PVA difficult to work with.

Be aware that some ABS manufacturers mix slightly cheaper polystyrene into their consumables. Accordingly, models made from such materials can be dissolved in Limonene along with supporting structures.

When polystyrene is heated to extrusion temperature, toxic fumes can be released, so printing in a well-ventilated area is recommended.

Wood simulants (LAYWOO-D3, BambooFill)

LAYWOO-D3 is a recent development for printing wood-like models. The material consists of 40% natural wood chips of microscopic size and 60% binder polymer. The LAYWOO-D3 is very easy to handle, being virtually warp-free and does not require the use of a heated platform. According to the manufacturers, the polymer is non-toxic and completely safe.

The unique material properties allow for different visual results when printing with different nozzle temperatures. The operating temperature range is 180°C-250°C. As the extrusion temperature increases, the shade of the material becomes progressively darker, allowing it to simulate different types of wood or annual rings.

Finished models are excellent for mechanical processing - grinding, drilling, etc. In addition, the products are easily painted, and unpainted models even have a characteristic woody smell.

Unfortunately, the cost of the material is almost four times higher than the price of popular materials such as PLA and ABS plastics. As popularity is projected to grow, the material should become more accessible.

Alternative materials are currently being developed and tested, such as BambooFill from the Dutch company ColorFabb.

Sandstone Simulators (Laybrick)

Composite from inventor Kai Parti, responsible for the revolutionary LAYWOO-D3 wood simulant. This time, Kai set his sights on sandstone imitation, using a tried and tested method of mixing a binder with a filler, in this case mineral.

Laybrick allows you to produce objects with different surface textures. At low extrusion temperatures of the order of 165°C-190°C, the finished products have a smooth surface. Increasing the printing temperature makes the material rougher, up to a high degree of resemblance to natural sandstone at extrusion temperatures above 210°C.

The material is easy to work with no need to heat the work platform, does not show significant deformation when shrinking and does not produce toxic fumes when heated. The only drawback can be considered a rather high cost of the material, which is largely due to limited production.

Metal Simulators (BronzeFill)

Metals have attracted additive manufacturing enthusiasts since the early days of 3D printing technology. Unfortunately, printing with pure metals and alloys causes a lot of difficulties that are insurmountable for most 3D printing methods. Fully functional metal products can only be produced using technologies such as SLS, DLMS or EBM, which require the use of industrial plants that cost hundreds of thousands of dollars.