Chloe Zhang
The strength of 3D-printed plastic parts depends on several factors, including the material used, the structural design, part orientation, and the printing process. Generally, plastic materials used in 3D printing are not as strong as metals and ceramics, but they are strong enough for a variety of applications. The most common thermoplastics used in 3D printing are Acrylonitrile Butadiene Styrene (ABS) and Polylactic Acid (PLA), but the strongest parts use industrial-grade thermoplastics such as Polycarbonate, Nylon, or Polyetheretherketone (PEEK). These materials are stronger than PLA and other plastic filaments used in consumer-grade 3D printers and offer excellent heat resistance and durability.
| Characteristics | Values |
|---|---|
| Material | Plastic, Metal, Ceramic |
| Plastic Types | ABS, PLA, Polycarbonate, Nylon, PETG, Polyethylene Terephthalate Glycol, ULTEM 1010, PEEK, Poly Ether Etherketone, EPX 82 Resin |
| Strength | Varies with material, layer height, line thickness, infill pattern, infill density, infill percentage, shell thickness, print speed, print settings, post-processing techniques, structural design, printer orientation, internal structure, printer calibration quality |
| Tensile Strength | Stiffness, maximum stress before deformation or breaking |
| Hardness | Measured on the Rockwell scale from A to K |
| Impact Resistance | Resistance to deformation or breakage when subjected to force or impact |
| Elongation (Ductility) | Extent to which a material can be deformed plastically without breaking |
| Heat Resistance | Nylon, PEEK, Polycarbonate |
| Other Factors | Fatigue properties, crack propagation, brittleness |
| Use Cases | Automotive, aerospace, medical, consumer products, electronics, wearable sensors, packaging, tools, food industry, oil and gas, semiconductor production |
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What You'll Learn
The impact of line width and layer height on strength
The strength of 3D-printed parts depends on several factors, including the material used, the structural design, part orientation, and the printing process. The bond strength of the successive layers is crucial to the overall strength of the products, as is the material, printer orientation, and internal structure.
Line width, which is related to nozzle diameter size, can influence the strength of 3D-printed parts. Thicker lines can provide stronger parts as there is more plastic for each layer to bond to. However, a bigger line width will result in less definition. A thinner line width may produce more detailed parts with greater dimensional accuracy but may not be as strong.
Layer height, or the thickness of each printed layer, also impacts the product's strength. Thinner layers produce a more robust product, while thicker layers tend to yield a weaker product. This is because thinner layers have more extrusions of material per part, and the low distance between the nozzle and the previous layer helps with bonding. However, thicker layers have fewer but thicker extrusions, and the strength of different layer heights can be roughly equivalent.
The printing time is inversely proportional to the layer height, so using layers that are half the thickness will roughly double the print time. Thinner layers also give a less noticeable "stair-step" effect and improve part precision.
To achieve the best print results in terms of strength, it is crucial to balance layer height, line thickness, and print time according to specific requirements.
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Material composition and ductility
The strength of 3D-printed parts depends on several factors, including the material used, the structural design, part orientation, and the printing process. Generally, plastic materials used in 3D printing are not as strong as metals and ceramics, but they are strong enough for a variety of applications.
The ductility of a material refers to its elongation, or the extent to which it can be plastically deformed when put under tensile stress before it fails. A high ductility level means a material can be stretched or elongated into a thin wire shape without breaking. A low ductility indicates that the material will fracture if deformed under a heavy load.
The most common thermoplastics used in 3D printing are Acrylonitrile Butadiene Styrene (ABS) and Polylactic Acid (PLA). ABS is a standard 3D printing material that is strong and impact-resistant, but not as strong as metals such as aluminium or steel. ABS produces fumes during printing, so it should be used in well-ventilated spaces and with an enclosed printer that has a filtration system.
PLA is another commonly used thermoplastic, but it is not as strong as industrial-grade thermoplastics such as Polycarbonate, ABS, or Nylon. Nylon is a strong and flexible material that is hard to print with and cannot be easily glued together. Polycarbonate is a tough and amorphous material with high impact strength, stability, and good electrical properties. It is widely considered the strongest 3D printed filament.
Other industrial-grade thermoplastics include Polyethylene Terephthalate Glycol (PETG), which combines the best qualities of PLA and ABS, and Poly Ether Ether Ketone (PEEK), which has excellent fatigue and stress-crack resistance and is used in aerospace, oil and gas, and semiconductor production.
The strength of 3D-printed plastic parts can be improved through fiber reinforcement, which increases durability and strength. However, not all desktop 3D printers can process fiber-reinforced filament, and those that can require a hardened steel nozzle to withstand the extra abrasion of the filled materials.
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Tensile strength and impact resistance
The strength of 3D-printed parts depends on several factors, including the material used, structural design, part orientation, and printing process.
Tensile strength, also known as elastic strength, measures a material's stiffness and is defined as the maximum amount of stress a material can tolerate before becoming deformed or breaking. It is measured in megapascals (MPa), with one MPa equalling one million pascals (Pa). Tensile strength is weaker along the Z-axis in 3D printing, especially in tall and thin printed parts. Increasing the shell thickness of a 3D-printed part can improve its tensile strength.
Polycarbonate (PC) is widely regarded as one of the strongest 3D printing filaments, delivering high tensile strength along with high impact and heat resistance. Other materials with high tensile strength include Poly Ether Ether Ketone (PEEK), carbon fibre filaments, and nylon.
PLA, a popular thermoplastic, exhibits a tensile strength of 50 MPa. However, it is more brittle than other materials such as ABS or PETG, which can lead to parts breaking under stress or impact. To enhance the tensile strength of PLA, post-processing methods such as annealing can be applied. Annealing involves heating parts in an oven to relieve internal stresses and improve layer adhesion, which can increase heat resistance and tensile strength.
Impact resistance measures a material's resistance to deformation or breakage when subjected to a sudden force or impact. Materials with high impact resistance include ABS, PP (Polypropylene), and HP 3D High Reusability PA 118. ABS is a widely used thermoplastic in 3D printing, known for its durability, high impact resistance, and overall strength. PP is commonly used in packaging applications and medical applications like prosthetics due to its impact resistance and flexibility. HP 3D High Reusability PA 118 is perfect for applications requiring impact resistance, such as prostheses, sports goods, and living hinges.
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The role of infill percentage and pattern
The infill percentage and pattern play a crucial role in determining the strength, structure, and weight of 3D-printed objects. Infill refers to the internal structures within 3D-printed components, which can be adjusted to balance printing time, material usage, and the strength of the final product.
Infill percentage, or infill density, is the extent of "fullness" inside a 3D-printed object. It is typically expressed as a percentage between 0% and 100%, where 0% indicates a completely hollow object and 100% indicates a completely solid object. The higher the infill percentage, the less flexible the part will be. The higher infill percentage, the stronger and heavier the object becomes, but this also increases printing time and material consumption. For example, a standard infill density for functional prints that require strength is between 20% and 30%. However, for lattice structures, densities above 35% may not provide a significant increase in strength. On the other hand, lower infill densities, such as 10%, result in quicker printing times, lower material usage, and reduced weight, but at the cost of reduced strength.
The choice of infill pattern also influences the strength of 3D-printed objects. Different patterns, such as honeycomb, tri-hexagon, and gyroid, are known to enhance structural integrity due to their uniform material distribution and load-bearing capabilities. Additionally, certain patterns like the concentric pattern are quicker to print and use less material, but they compromise part strength, especially when subjected to loads in the x or y directions. In contrast, the grid pattern, characterized by a cubic grid with intersecting plastic at 90-degree angles, is suitable for large, flat surfaces but may cause nozzle clogging. Another pattern, the line infill, enhances strength in two dimensions by using multiple parallel lines per layer that intersect the preceding layer at a 90-degree angle without overlapping on the same layer.
It is important to note that the optimal infill pattern and percentage depend on the specific requirements of the part being printed, the available resources, and the intended application. For instance, simpler patterns like grid or line patterns often yield satisfactory results, and lattice structures are preferred when the part needs to have some functionality due to their isotropic strength properties. Ultimately, finding the right combination of infill percentage and pattern involves experimentation and evaluating the balance between printing time, material usage, and the desired strength of the final product.
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Post-processing techniques and printing settings
Post-processing techniques are an important step in the 3D printing process, enhancing and refining the printed object. Post-processing can be costly and time-consuming, especially when done manually. However, advancements in technology have led to the development of automated post-processing equipment, making the process more efficient and scalable.
One common post-processing technique is removing support or excess material. This can be done manually or through automated solutions that vibrate or rotate the object to remove excess powder. Another technique is sanding or polishing, which smooths the surface and improves strength. This can be achieved by hand or with machines, using various abrasives such as sandpaper, steel wool, or polishing paste. Solvents can also be used to smooth 3D prints, but caution is required as overexposure can deform and weaken the object.
Other post-processing methods include vinyl wrapping, which enhances aesthetics and provides heat and stress resistance. Painting and colouring are also popular techniques, with the option to print using coloured material or add colour during post-processing. Additionally, epoxy coating and annealing are effective methods for strengthening 3D prints, with annealing causing a significant increase in strength by reorganizing the crystalline structure of the plastic.
Printing settings also play a crucial role in determining the strength of 3D printed plastic parts. The print orientation is critical, as parts are strongest in planes parallel to the print bed. Triangular infill patterns provide superior strength and support, while rectangular infill can achieve 100% density. Layer height and bead cross-section balance each other out, resulting in similar strength across different layer heights. The number of walls and their thickness contribute to overall strength, with thicker walls providing better reinforcement.
The choice of material is significant, as some plastics are inherently stronger. For instance, ABS is a lightweight thermoplastic suitable for strong prints, while PLA is a more expensive option for heavy-use and high-resolution prints. Additionally, continuous fiber filaments, such as carbon fiber, fiberglass, or Kevlar, can significantly enhance the strength of the printed part.
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Frequently asked questions
The strength of 3D-printed plastic parts depends on several factors, including the material used, the structural design, part orientation, and the printing process. Generally, plastic materials used in 3D printing are not as strong as metals and ceramics, but they are strong enough for a variety of applications.
The strongest plastics for 3D printing include industrial-grade thermoplastics such as Polycarbonate, Acrylonitrile Butadiene Styrene (ABS), and Nylon. Polycarbonate is widely considered the strongest 3D printed filament. Nylon PA 12 CF is widely referred to as the FDM material with the highest strength-to-weight ratio available.
There are several ways to improve the strength of 3D-printed parts:
- Use fiber reinforcement
- Adjust the layer height and line width
- Slow down the print speed
- Increase the shell thickness
- Increase the infill percentage
