Chloe Zhang
3D printing has evolved to include a wide range of materials, including plastics with various properties such as flexibility, strength, and biocompatibility. The most common plastic used in 3D printing is Acrylonitrile Butadiene Styrene (ABS), known for its impact resistance and flexibility. Other plastics like PET, PEEK, and ULTEM are also used, each offering unique advantages. Preparing plastic for 3D printing involves recycling plastic into filament, sorting by type, and ensuring accuracy to prevent printer nozzle clogging.
| Characteristics | Values |
|---|---|
| Commonly used plastic | Acrylonitrile butadiene styrene (ABS) |
| ABS properties | High strength, polished surface, reusable, weldable with acetone, flexible, impact-resistant, tolerates very low and high temperatures |
| ABS printing temperature | 230°C to 160°C |
| ABS printing considerations | Shrinks in contact with air, so the build platform must be heated |
| Other plastics | Polyethylene terephthalate (PET), High Impact Polystyrene (HIPS), Polyvinyl Acetate (PVA), Butene-diol Vinyl Alcohol Copolymer (BVOH), PEEK, PEKK, ULTEM |
| PET properties | Semi-rigid, good resistance, no odour during printing, 100% recyclable |
| PET printing temperature | 75°C to 90°C |
| HIPS properties | Can be dissolved with limonene |
| PVA properties | Water-soluble, used as a support structure for other materials |
| BVOH properties | More soluble than PVA, popular in dual-extruder printers |
| High-performance plastics | PEEK, PEKK, ULTEM |
| High-performance plastic properties | High mechanical and thermal resistance, significantly lighter than metals |
| High-performance plastic printing requirements | 3D printer must have a hot plate capable of 230°C, extrusion at 350°C, and a closed chamber |
| Plastic recycling | Possible to recycle plastic into 3D printer filament at home with an extrusion line |
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What You'll Learn
Types of plastic: ABS, PET, PEEK, PEKK, ULTEM
When loading plastic into a 3D printer, it is important to consider the type of plastic being used, as different plastics have different properties and requirements. Here is an overview of the types of plastic mentioned: ABS, PET, PEEK, PEKK, and ULTEM.
ABS
Acrylonitrile butadiene styrene (ABS) is the most commonly used plastic in the 3D printing industry. It is a thermoplastic with a flexible and impact-resistant elastomer base. ABS has a printing temperature range of 230°C to 160°C and can withstand very low and high temperatures (-20°C to 80°C). It offers high strength, a polished surface, reusability, and weldability. However, ABS is not biodegradable and shrinks in contact with air, requiring a heated build platform during printing.
PET
Polyethylene terephthalate (PET) is commonly found in disposable plastic bottles. It is a semi-rigid, food-safe filament with good resistance. PET is typically marketed as a translucent filament but comes in different varieties. It prints best at temperatures between 75°C and 90°C and does not release any odour during printing. PET is also 100% recyclable.
PEEK and PEKK
Polyether ether ketone (PEEK) and polyether ketone ketone (PEKK) are high-performance polymers offering dimensional stability, exceptional heat resistance, high strength, and broad chemical resistance. They are semi-crystalline in structure, making them difficult to print as they require extremely high extrusion and bed temperatures. PEEK and PEKK are used in demanding industries such as aerospace, automotive, electrical, and medical due to their high-performance characteristics.
ULTEM
ULTEM, a brand name for PEI products, is an amorphous resin blend with high heat resistance, mechanical strength, and low toxicity. It is much easier to print than PEEK and PEKK, extruding at a lower temperature. ULTEM is widely used in marine, aerospace, and oil and drilling sectors due to its desirable flame, smoke, and toxicity ratings, as well as its high strength-to-weight ratio.
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Choosing a printer: FDM, SLS, SLA, or material jetting
When it comes to choosing a 3D printer, there are several options available, each with its own advantages and disadvantages. The most common types of 3D printers are FDM, SLS, SLA, and material jetting printers.
FDM (Fused Deposition Modeling), also known as FFF (Fused Filament Fabrication), is the most well-known and widely used 3D printing technology. FDM printers work by extruding molten plastic or a thermoplastic polymer through a heated nozzle in a prescribed shape, then moving up and depositing the next layer on top. The resolution of FDM 3D printed parts depends on the nozzle size, the material properties of the molten material, and the control of the motor. FDM printers typically create walls around 0.8 mm thick and struggle with complex designs compared to SLA printers. ABS (Acrylonitrile Butadiene Styrene) is the most commonly used plastic in FDM printers and is available for most desktop 3D printers. FDM printers are also capable of printing with metal filaments.
SLA (Stereolithography) is the second most popular 3D printing process and offers a wide range of materials and applications. SLA printers use a laser beam or digital light projector to harden a photopolymer resin layer-by-layer on a platform. SLA parts have smooth surfaces, superior dimensional accuracy, and tight tolerances, making them ideal for demanding applications like restorative models in dentistry. SLA materials can be formulated with a range of optical, mechanical, and thermal properties, including specialized features such as flame retardancy or biocompatibility. SLA printers do not require support structures, making it easier to prepare detailed projects with sharp edges and thin walls.
SLS (Selective Laser Sintering) is another popular 3D printing technology that offers designers the freedom of form. SLS printers use a laser to sinter together powder particles in the desired shape, creating parts with movable, complicated geometries. Like SLA printers, SLS printers do not require support structures, allowing for more detailed projects with sharp edges and thin walls. SLS printers can create layer thicknesses between 0.06 and 0.15 mm, making them very precise. The powder used in SLS printers is also reusable after printing, and desktop SLS printers are relatively inexpensive compared to industrial machines.
Material jetting is a process where liquid photopolymers or wax-like materials are jetted onto a build platform through print heads. This technology allows for the creation of highly detailed parts with complex geometries and smooth surfaces. Material jetting printers can use a variety of materials, including plastics and metals, and are known for their speed and accuracy.
In summary, FDM printers are the most common and affordable option, while SLA and SLS printers offer more advanced capabilities and precision but may be more expensive. Material jetting printers provide excellent detail and speed but may be more specialized and costly. The choice between these technologies depends on the specific requirements and budget of the user.
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Preparing plastic: Grinding, washing, and sorting
Preparing plastic for 3D printing is a great way to recycle plastic waste and prevent it from ending up in landfills. The process involves grinding, washing, and sorting plastic waste to create custom objects, furniture, and even architectural components.
Firstly, collect plastic waste such as bottles, containers, and other discarded plastics. It is important to separate different types of plastics to avoid material contamination, as they react differently to heat and do not always mix well. The dirt can clog your extrusion line, pollute your filament, or clog your 3D printer nozzle. Wash the plastic thoroughly to remove any residue.
Next, use a shredder or grinder to break the plastic into small bits or granules suitable for extrusion. You can use a store-bought shredder or build your own grinder. One option is to use an electric hand plane fixed on a heavy wrench, with a vacuum cleaner bag to catch the ground output. However, this method may require some disassembly as plastic can get wedged in places. Another option is to use an old coffee grinder for a finer grind.
Finally, melt the shredded plastic and extrude it into small pellets or flakes, which can be used as feedstock for an FGF 3D printer. Load the pellets into the 3D printer's hopper and print your object layer by layer.
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Extruding plastic: Using an extrusion line
Extruding plastic is a high-volume manufacturing process that can produce a wide range of products with different shapes, sizes, and profiles. It is a continuous process that is suitable for mass production and meeting large-scale demand. The process involves melting raw plastic and forming it into a continuous profile. This can be done using an extrusion line, which has two parts: upstream and downstream.
On the upstream side, auxiliary equipment receives, mixes/blends, and delivers resin and other ingredients to the extrusion machine. The extruder then melts the plastic and delivers a continuous, pressurised stream of extrudate to all of the downstream tools and equipment. The downstream auxiliary equipment then forms, cools, and hardens the extrudate into its finished shape, which can include rolls of plastic film, pipes, sheets, and more.
The size of the extruder will depend on the desired output. Smaller extruders can produce fine filaments or small-diameter tubing, while larger extruders can process thousands of pounds of material per hour into thick-walled plastic pipes or plastic-composite lumber. Each extruder is controlled by a master extrusion control, which regulates the speed of the downstream equipment to maintain the dimensional consistency and physical characteristics of the extruded product.
The temperature of the extrusion process is very important to the quality of the final product. Typically, a heating profile is set for the barrel, with independent heater zones gradually increasing the temperature from the rear to the front. This allows the plastic to melt gradually and lowers the risk of overheating, which can cause polymer degradation. Cooling is typically achieved by pulling the extrudate through a water bath, although air cooling may be used for films and very thin sheeting.
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Printing process: Temperature, speed, and accuracy
Printing with plastic requires careful calibration of temperature, speed, and accuracy to ensure the best results. The printing temperature depends on the type of plastic used. For example, the commonly used plastic Acrylonitrile Butadiene Styrene (ABS) has a printing temperature between 230°C and 160°C. Polyethylene Terephthalate (PET) requires temperatures of 75°C to 90°C. High-performance plastics like PEEK, PEKK, and ULTEM require 3D printers with a hot plate capable of reaching at least 230°C, extrusion at 350°C, and a closed chamber.
The room temperature for 3D printing is also important, especially when using certain plastics like PLA filament, which works best in a temperature range between 20°C and 25°C. Printing in a cold room can cause issues with poor filament flow and inadequate adhesion, leading to problems like delamination or warping.
Temperature and print speed are closely related in 3D printing. Higher print speeds require higher temperatures to ensure the filament melts properly and flows smoothly, while lower speeds allow for reduced temperatures without compromising the print. Adjusting the temperature and speed settings depends on the print size and complexity. Smaller, intricate prints benefit from slower speeds and lower temperatures, while larger models may require higher settings.
Finding the right balance between print speed and temperature is crucial to achieving the desired results. Increasing the temperature when increasing the speed ensures the filament melts properly. Conversely, reducing the temperature is necessary when decreasing the speed to avoid issues like over-extrusion or stringing.
Cooling fans play a vital role in managing the temperature of the freshly extruded filament, helping it solidify in place. Balancing fan speed is essential for print accuracy. If the fans are too strong, they can cause layer separation or cracking. Additionally, proper ventilation and cooling are necessary to prevent the stepper motors, which control the movement of the print head and build platform, from overheating and causing missed steps or decreased precision.
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Frequently asked questions
Acrylonitrile butadiene styrene, or ABS for short, is the most commonly used plastic in the industry. It is flexible, impact-resistant, and has a high strength.
Polyethylene terephthalate, or PET, is ideal for objects intended for food contact. It is semi-rigid, has good resistance, and does not release odour during printing.
PEEK, PEKK, and ULTEM plastics are high-performance polymers with very high mechanical and thermal resistance, making them popular in the aerospace, automotive, and medical sectors.
Polyvinyl acetate, or PVA, is a water-soluble plastic commonly used as a support structure for specific parts of a product. It can be dissolved in water after printing, leaving the final product intact.
Yes, it is possible to recycle plastic into 3D printer filament at home. However, it requires a process to grind and sort the plastic, as well as an extrusion line to create the filament.
