This in-depth overview explores the widely used plastic and metal materials for 3D printing, contrasts their characteristics and uses, and provides a structured approach to help you select the optimal material based on your specific requirements and goals.
Plastic 3D printing
Plastic 3D printing has revolutionized manufacturing, allowing for faster prototyping and custom part production across various industries. To leverage its full potential, understanding the types of plastic materials and processes available is key. Each material and process combination provides distinct advantages, suited to different applications based on factors like strength, durability, flexibility, and surface quality.
Types of Plastic Materials
3D printing materials are categorized into thermoplastics, thermosetting plastics, and elastomers. Each of these materials behaves differently under heat and stress, which directly impacts the suitability of their applications.
| Material Type | Key Properties | Common Applications |
| Thermoplastics | Re-meltable and reusable; typically strong and flexible | Prototypes, mechanical parts, enclosures |
| Thermosetting Plastics | Harden permanently after curing; excellent heat resistance | Electrical insulators, casting, industrial components |
| Elastomers | Rubber-like, highly elastic and flexible | Wearables, seals, flexible connectors |
Thermoplastics: These are the most commonly used materials in 3D printing because they can be melted, reshaped, and recycled. This makes them versatile for a range of products.
Thermosetting Plastics: Once hardened, these materials cannot be melted again. Their high temperature and chemical resistance make them suitable for industrial parts and components exposed to extreme conditions.
Elastomers: Known for their stretchability and flexibility, elastomers are ideal for parts that require flexibility or repeated deformation without breaking.
More details about Thermoplastics vs. Thermosetting Materials.
Plastic 3D Printing Processes
Each 3D printing process offers unique benefits in terms of cost, detail, and material options. The choice of process depends on the required part quality, durability, and production speed.
| Process | Advantages | Disadvantages |
| FDM (Fused Deposition Modeling) | Low cost, easy setup, and wide material availability | Limited resolution, visible layer lines, slower for high detail |
| SLA (Stereolithography) | High resolution, smooth surface finish | More expensive, resins can be brittle |
| SLS (Selective Laser Sintering) | High strength, good for complex geometries, no supports needed | High cost, rough surface finish, powder handling required |
FDM: Known for its affordability and accessibility, FDM is ideal for rapid prototyping or large, less detailed models. It is popular in educational settings and hobbyist applications due to the low entry cost of the equipment.
SLA: SLA produces very high-resolution parts, making it perfect for intricate models that require smooth finishes, such as those used in jewelry or dentistry. However, the materials can be brittle, limiting their use for functional prototypes.
SLS: SLS’s ability to print strong, durable parts without needing support structures makes it ideal for functional prototypes and parts with complex internal geometries. The downside is its higher cost and the need for post-processing to improve surface finish.
FDM 3D Printing
FDM, or Fused Deposition Modeling, is the most widely adopted 3D printing technology. It is popular for its simplicity, cost-effectiveness, and the variety of thermoplastic filaments available.
Popular FDM 3D Printing Materials
| Material | Characteristics | Ideal Applications |
| PLA | Biodegradable, easy to print, and low cost | Prototypes, hobby models, visual aids |
| ABS | Strong, impact-resistant, and heat-resistant | Functional parts, automotive components |
| PETG | Flexible, stronger than PLA, and chemical resistant | Containers, mechanical parts, functional prototypes |
| TPU | Flexible, rubber-like, highly elastic | Gaskets, footwear, flexible parts |
PLA: It’s biodegradable and widely available, making it a go-to material for prototyping and educational projects. However, it lacks the durability required for long-term functional use.
ABS: This material is preferred in the automotive and electronics industries because it offers a good balance between strength, heat resistance, and toughness. However, it requires a heated bed and ventilation due to emissions during printing.
PETG: Combining the ease of PLA and the strength of ABS, PETG is commonly used for functional parts that need to withstand stress and exposure to chemicals.
TPU: TPU is a flexible filament with rubber-like properties, making it ideal for parts that require durability and flexibility, such as wearable tech or seals.
SLA 3D Printing
SLA (Stereolithography) uses a UV laser to cure liquid resin into solid parts, layer by layer. It excels in creating highly detailed and smooth-finish objects, making it particularly suitable for industries where precision is critical.
Popular SLA 3D Printing Materials
| Material | Characteristics | Common Uses |
| Standard Resins | High detail, smooth finish, brittle | Aesthetic prototypes, detailed models |
| Tough Resins | Impact-resistant, better durability | Functional parts, mechanical assemblies |
| Castable Resins | Burn out cleanly for investment casting applications | Jewelry, dental casting |
| Flexible Resins | Rubber-like flexibility, low elongation at break | Grips, wearables, soft-touch components |
Standard Resins: These are widely used for creating highly detailed and visually appealing models but are often too brittle for functional use.
Tough Resins: Designed for parts that require more strength and durability, these resins are ideal for functional prototypes where the material must withstand mechanical stress.
Castable Resins: These resins burn away cleanly, making them ideal for casting metal parts, such as jewelry or dental crowns, where precision is vital.
Flexible Resins: Offering rubber-like properties, these resins can be used in applications requiring both detail and flexibility, such as soft grips or wearable devices.
SLS 3D Printing
Selective Laser Sintering (SLS) is a powerful 3D printing process that uses a laser to sinter powdered plastic, creating highly durable parts without the need for support structures. SLS is commonly used in industries like aerospace and automotive for creating functional parts.
Popular SLS 3D Printing Materials
| Material | Characteristics | Ideal Uses |
| Nylon (PA12, PA11) | Strong, durable, and resistant to wear and chemicals | Functional prototypes, mechanical parts, enclosures |
| Glass-Filled Nylon | Increased stiffness and heat resistance | High-stress parts, industrial applications |
| TPU | Elastic, durable, rubber-like properties | Wearables, flexible connectors, gaskets |
| Alumide | Nylon mixed with aluminum powder, heat resistant | Stiff parts, enhanced mechanical properties |
Nylon: Known for its strength and durability, nylon is perfect for functional prototypes and production parts. Its resistance to wear and chemicals makes it a go-to material for mechanical and industrial applications.
Glass-Filled Nylon: Adding glass fibers increases stiffness and heat resistance, making it suitable for high-stress, high-temperature applications such as automotive engine components.
TPU: Like its use in FDM, TPU in SLS is excellent for producing flexible parts with good durability, such as seals, gaskets, and wearable tech.
Alumide: This composite material is a mix of nylon and aluminum powder, offering enhanced mechanical strength and heat resistance, making it a good choice for industrial parts that need extra rigidity and durability.
Comparison of 3D Printing Materials and Processes
| Feature | FDM | SLA | SLS |
| Resolution | Low to medium | Very high | Medium |
| Surface Finish | Visible layer lines | Smooth, glossy | Rough, grainy |
| Strength | Moderate (depends on material) | Low to medium | High (especially with Nylon) |
| Cost | Low | Medium to high | High |
| Complex Geometries | Support structures required | Support structures required | No supports needed |
FDM: Best for low-budget prototyping and functional parts with less emphasis on aesthetics.
SLA: Ideal for highly detailed, visually pleasing parts, though not as strong as FDM or SLS parts.
SLS: Provides the best balance of strength and complexity for functional prototypes and small-batch production, albeit at a higher cost.
Metal 3D Printing
Metal 3D printing is primarily used for high-performance applications in industries like aerospace, automotive, and medical fields. It enables the creation of lightweight, strong, and complex geometries that would be impossible with traditional manufacturing.
Popular Metal 3D Printing Materials
| Material | Characteristics | Common Applications |
| Stainless Steel | Corrosion-resistant, durable | Medical implants, tooling, aerospace parts |
| Aluminum | Lightweight, corrosion-resistant, moderate strength | Aerospace, automotive, lightweight structures |
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Titanium | Extremely strong, lightweight, and biocompatible | Medical implants, aerospace, performance parts | | Inconel | High-temperature and corrosion-resistant nickel alloy | Turbine blades, heat exchangers, exhaust systems |
Metal 3D printing materials are chosen based on the specific application requirements, such as heat resistance, corrosion resistance, or biocompatibility for medical use.
Alternatives to Metal 3D Printing
If full metal 3D printing isn’t necessary but you still need enhanced properties, there are alternatives like composite filaments or metal-infused plastics.
| Alternative | Characteristics | Ideal Applications |
| Composite Filaments | Lightweight, increased stiffness, easy to print | Functional prototypes, lightweight parts |
| Metal-infused Plastic | Simulates the look and feel of metal, lower cost | Decorative parts, artistic projects |
These materials allow for metal-like properties without the complexity or cost of full metal 3D printing, making them ideal for functional parts that don’t require extreme strength.
Step-by-step Guidance for Choosing the Right 3D Printing Material
1. Define Your Application Requirements
Start by clearly outlining what you need your 3D printed part to do:
What are the necessary mechanical properties (strength, flexibility, durability)?
Will it be exposed to heat, chemicals, or other environmental factors?
Does it need to be food-safe, biocompatible, or meet other safety standards?
What is the desired surface finish and appearance?
2. Consider Your 3D Printing Process
The 3D printing technology you use will influence your material options:
FDM (Fused Deposition Modeling) printers use thermoplastic filaments like PLA, ABS, PETG, and Nylon.
SLA (Stereolithography) and DLP (Digital Light Processing) printers use photopolymer resins.
SLS (Selective Laser Sintering) printers typically use powdered Nylon or TPU.
Metal 3D printers use powdered metals like stainless steel, titanium, and aluminum alloys.
3. Match Material Properties to Application Requirements
Research the properties of the materials compatible with your printer and compare them to your application needs:
For strength and durability, consider ABS, Nylon, or PETG.
For flexibility, look into TPU or TPC.
For heat resistance, ABS, Nylon, or PEEK are good options.
For food safety or biocompatibility, use dedicated food-grade or medical-grade materials.
4. Evaluate Ease of Use and Post-Processing
Consider the practicalities of working with each material:
Some materials, like PLA, are easier to print with than others, like ABS, which may require a heated bed and enclosed printer.
Resin prints need to be washed and post-cured, while filament prints may need support removal and sanding.
Some materials allow for smoothing, painting, or other post-processing techniques to enhance the final result.
5. Factor in Cost and Availability
Finally, consider the cost and accessibility of the materials:
Common filaments like PLA and ABS are generally less expensive and widely available.
Specialty materials like carbon fiber or metal-filled filaments may cost more and be harder to find.
Resins and metal powders for SLA, DLP, SLS, and metal printers tend to be pricier than filaments.
Conclusion
3D printing materials have vastly expanded, offering diverse options for a wide range of applications. When choosing a material, consider your specific requirements, such as mechanical properties, thermal stability, and chemical resistance. By understanding the properties and applications of each material, you can select the best option for your 3D printing project.
For expert guidance on your 3D printing project, contact us. Our experienced engineers provide 24/7 technical support and patient guidance on optimizing whole process. Partner with TEAM FMG for success. We will take your production to the next level.
3D Printing Materials FAQ (Concise)
1. What are the most common 3D printing materials?
Thermoplastics like PLA, ABS, PETG, and Nylon.
2. What's the difference between PLA and ABS?
PLA: Plant-based, easy to print, less strong and heat-resistant.
ABS: Petroleum-based, strong and heat-resistant, prone to warping.
3. What flexible 3D printing materials are available?
TPU (Thermoplastic Polyurethane) and TPC (Thermoplastic Co-polyester).
4. Can you 3D print metal parts?
Yes, with specialized metal 3D printers or by post-processing plastic prints.
5. Are 3D printed plastics food-safe?
Not standard plastics like PLA and ABS, but specific food-grade materials like PET and PP are.
6. What's the difference between 3D printing resins and filaments?
Resins: Used in SLA, produce high-resolution but brittle parts.
Filaments: Used in FDM, produce strong and stable parts, most common.
7. How can you recycle 3D printing materials?
Grind and re-extrude plastics, collect and sort for recycling, or industrially compost PLA.
