Maya Ellison
Plastic is everywhere, from food packaging to medical equipment. So, it's no surprise that printing on plastic materials and using plastic as a printing material are important considerations in the world of printers. Plastic plays a role in both the construction of printers and as a material used for printing. Different types of plastics offer unique advantages and present specific challenges, requiring careful selection of printer types and techniques to ensure optimal results. This includes considerations such as print quality, production volume, environmental factors, and the specific characteristics of the plastic being printed on or used as a printing material. Understanding the interplay between plastic types and printer technologies is essential for achieving desired outcomes in various industrial, creative, and packaging applications.
| Characteristics | Values |
|---|---|
| Common plastic used in 3D printing | Acrylonitrile butadiene styrene (ABS) |
| Other plastics used in 3D printing | Polylactic acid (PLA), High-density polyethylene (HDPE), Polyvinyl Acetate (PVA), Polyethylene Terephthalate (PET), Polyvinyl Chloride (PVC), Polypropylene (PP), Low-density polyethylene (LDPE), Polystyrene/Styrofoam (PS), Polycarbonate, Polyurethane, Acrylic |
| Plastic filaments that are soluble in water | PVA, BVOH |
| Plastic filaments soluble in limonene | HIPS |
| Plastic filaments that are flexible | TPE, TPU |
| Plastic filaments that are wood-like | Woodfill |
| Plastic filaments that are high-performance | PEEK, PEKK, ULTEM, PAEK, PEI |
| Types of printers that can print on plastic | Inkjet printers, laser printers, thermal printers, UV printers, digital printers, flexographic printers, pad printers, screen printers |
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What You'll Learn
Types of plastic used in 3D printing
Plastic is the most common raw material for 3D printing. Its strength, smoothness, flexibility, and cost-effectiveness make it a highly diverse material for 3D-printed products. The most common types of plastic used in 3D printing are:
Acrylonitrile Butadiene Styrene (ABS)
ABS is the same plastic used in Lego bricks. It is tough, nontoxic, and retains colour well. It is also easy to shape, but tough to break, as it melts and becomes pliable at about 220°C. It is mainly used in fused layer technology (FLT) and is available for most desktop 3D printers. ABS is also available in resin form, making it suitable for stereolithography (SLA) or material jetting processes. ABS is mainly used to manufacture stickers, toys, vases, and jewellery.
Polylactic Acid (PLA)
PLA is a polymer plastic made from biological materials like corn starch or sugarcane. It is similar to the material used in biodegradable plastic packaging and melts at between 180°C and 200°C, depending on other materials added for colour and texture. PLA is a tough, resilient material with a matte, opaque quality. It is generally the preferred option for low-cost 3D printers, as it is easier to print with than ABS.
High-Density Polyethylene (HDPE)
HDPE, also known as high-impact polystyrene or HIPS, is used in pipes and recyclable packaging. It is a light, flexible material that sticks to itself and other materials well. It is also easy to dye and mould. It melts at about 230°C, but releases unpleasant fumes if accidentally heated to higher temperatures. In 3D printing, HDPE is often used instead of ABS, as comparable prints turn out lighter and stronger.
Polyvinyl Acetate (PVA)
PVA is a water-soluble plastic commonly used to create a support structure for specific parts of a product that may otherwise warp or collapse during the printing process. It is not suitable for products that need high strength but is ideal for those with temporary use and a dissolvable quality. PVA is also used as a glue or packaging stretch film.
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Plastic printer suitability
Plastic Type
The type of plastic you want to print on is crucial when selecting a suitable printer. Different plastics have distinct characteristics that affect the printing process. Common plastics used in various applications include:
- Polyethylene Terephthalate (PET): Commonly used in beverage bottles, food packaging, and textiles. PET is known for its strength, flexibility, and clear appearance.
- Polyvinyl Chloride (PVC): A versatile plastic used in construction materials, medical devices, and credit cards. PVC can be made flexible with plasticizers.
- High-Density Polyethylene (HDPE): Found in items like detergent bottles, plastic bags, and toys. HDPE is valued for its durability, chemical resistance, and high strength.
- Polypropylene (PP): Known for its toughness and heat resistance, PP is used in automotive parts, containers, and special fibers.
- Low-Density Polyethylene (LDPE): Used for plastic bags and squeezable bottles. LDPE is softer, flexible, and resistant to acids, bases, and oils.
- Polystyrene/Styrofoam (PS): Rigid polystyrene is used in cutlery and CD cases, while Styrofoam is used for packing materials and food containers.
- Miscellaneous Plastic Polymers: This includes polycarbonate, polyurethane, and acrylic, used in applications ranging from bulletproof windows to foam seating.
Printer Type
Different types of printers are suitable for printing on plastic, each with its advantages and applications:
- Standard Inkjet Printers: Versatile and capable of producing high-detail, full-colour images on plastics like PET and PVC.
- Digital Printers: Ideal for detailed, custom designs and can handle almost any type of plastic. They are particularly useful for short runs and on-demand printing.
- Flexographic Printers: Used for large-scale printing on plastic films like LDPE and HDPE, creating continuous patterns using flexible plates and fast-drying inks.
- Pad Printers: Suitable for three-dimensional objects and irregular surfaces like toys and medical devices.
- Screen Printers: Ideal for high-volume, durable prints on items like plastic containers and promotional products.
- Laser Printers: Produce high-quality, precise, and detailed prints using a focused laser beam to heat and melt the plastic surface.
- Handheld Thermal Inkjet Printers: Portable printers that use heat to expel ink droplets onto the plastic surface, ideal for small-scale, detailed printing on plastic substrates, including packaging and labelling.
Printing Technology
The choice of printer also depends on the printing technology compatible with the specific type of plastic:
- FDM (Fused Layer Technology) Printers: Used for plastics like ABS, HIPS, and some high-performance polymers. These printers require a heated print bed and can handle high temperatures.
- SLA or Material Jetting: Suitable for ABS resin, creating reusable and weldable parts with a polished surface.
- 3D Printing with Soluble Materials: HIPS and PVA are soluble filament materials used to create support structures for specific parts, which can be dissolved in limonene or water, respectively.
- 3D Printing with Woodfill Filament: Contains fine wood particles combined with PLA, creating a wood-like appearance when polished.
In summary, choosing the right printer for plastic products depends on understanding the characteristics of different plastics and selecting a printer type and technology compatible with your specific requirements, including the type of plastic, print quality, and application.
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Plastic printing methods
Plastic is a versatile material that can be printed on using various methods. The most common techniques for printing on plastic include screen printing, pad printing, and laser etching.
Screen Printing
Screen printing operates on the principles of "blocking" and "ink permeability." The process involves creating a screen frame, typically made of wood or metal, and stretching a fine nylon or polyester mesh over it. A layer of photosensitive emulsion is then applied to the screen and exposed to light, hardening the emulsion. The prepared design pattern is placed over the screen, and it is exposed to light again. This method offers durable and thick ink layers, vibrant colours, and cost-effectiveness for mass production.
Pad Printing
Pad printing is versatile and can be applied to various materials, including plastics, metals, glass, ceramics, and wood. It is adaptable to different colours of ink and is efficient for rapid production and small-batch customization. However, similar to screen printing, each print cycle can only apply one colour, making multicolour printing more time-consuming and costly.
Laser Etching
Laser etching, also known as laser printing, uses a high-powered laser to etch intricate designs onto the plastic. This method offers precision and is often used for permanent, complex designs and industrial applications. Laser etching can also involve using a stencil to apply ink to the plastic surface.
Other Plastic Printing Methods
Other notable plastic printing methods include digital printing, which uses inkjet technology to produce high-quality images directly onto plastic surfaces, and flexographic printing, which uses flexible rubber plates to transfer ink onto plastic for medium-size production runs. For small-scale production, thermal transfer printers use heat to transfer ink onto plastic surfaces. Finally, hot stamping is a cost-effective method that uses heat and pressure to transfer ink from a foil onto plastic, making it ideal for printing plastic bags.
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Plastic printing applications
Plastic is a versatile material with a wide range of applications in printing. It is used as a printing base material for various purposes, from retail signage to vehicle advertising and industrial labelling to creative projects. Its long life expectancy, durability, and weather resistance make it a preferred choice over paper-based products for long-term use. Clear plastic is especially sought-after for signage applications as it offers an elegant look.
Plastic is also commonly used in 3D printing, with Acrylonitrile Butadiene Styrene (ABS) being the most popular choice due to its toughness, non-toxicity, and ability to retain colour. It is widely used in car bodies, household appliances, and roofing applications. Other plastics used in 3D printing include Polylactic Acid (PLA), a polymer plastic made from biological materials like cornstarch or sugarcane, known for its toughness and resilience; High-Density Polyethylene (HDPE), a flexible and mouldable material used in pipes and packaging; and Polyethylene Terephthalate (PET), commonly found in disposable plastic bottles and ideal for objects intended for food contact.
High-performance plastics, such as PEEK, PEKK, and ULTEM, are also used in 3D printing, particularly in the aerospace, automotive, and medical sectors due to their high mechanical and thermal resistance. These plastics require specific printers capable of reaching high temperatures.
Different printing processes are employed for printing on plastic, including flexo printing, UV lithography, pad printing, laser printing, and handheld thermal inkjet printing, each offering unique advantages and suitability for specific applications.
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Plastic printing challenges
Plastic is a durable, versatile, and easy-to-print material, making it perfect for marketing materials like business cards, brochures, and signs. However, businesses often find it challenging to start plastic printing with a proper process. One of the most common challenges associated with plastic printing is that certain plastics have very smooth surfaces, which can cause issues with ink adhesion, resulting in smudging or smearing. Some plastics are also more absorbent than others, and some may be sensitive to heat, meaning that they can warp or melt when exposed to high temperatures during the printing process. Therefore, it is important to select a machine that is specifically designed for the type of printing being done.
Another challenge is finding the right plastic for the job. There are multiple types of plastic available for printing jobs, each with its own unique characteristics. For example, polystyrene provides good impact resistance but poor solvent resistance, while polypropylene offers superior clarity for transparent products. The intended use, thickness, printability, and compatibility with printing technology must also be considered. Any impurity, dust, grime, dirt, or debris can severely impact printing, so the plastic must be clean before starting the job.
Additionally, the printing machine must be compatible with the plastic type and printing method. Thermoforming, extrusion, and injection molding are the most popular methods, and each has its own unique requirements that must be followed. This can be a daunting task, and many businesses choose to consult a third-party printing provider to ensure they are using the correct process.
Overall, while plastic printing can be challenging, with careful planning and execution, it is possible to produce high-quality prints on a variety of plastic materials.
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