Chloe Zhang
3D printing has traditionally been associated with plastic, and it remains the most popular 3D-printing material. However, as the 3D-printing market value increases, the variety of materials that can be used is also growing. Raw materials such as metal, carbon fibre, and even wood are now used for 3D printing. The most common FDM 3D printing materials are ABS, PLA, and their various blends. The most established plastic 3D printing processes are FDM, SLA, and SLS.
| Characteristics | Values |
|---|---|
| Most commonly used plastic | Acrylonitrile butadiene styrene (ABS) |
| Most commonly used plastic properties | High strength, polished surface, reusable, weldable with acetone, impact-resistant, flexible, high and low-temperature tolerance |
| Other common plastics | Polyethylene terephthalate (PET), Polypropylene, Nylon, PLA, PVA, HIPS, BVOH |
| Other common plastics properties | PET: semi-rigid, good resistance, no odour, recyclable. Polypropylene: light, high mechanical and thermal resistance. Nylon: difficult to print. PLA: basic, low-cost prototyping. PVA: water-soluble support structure. HIPS: soluble with limonene. BVOH: soluble in water |
| Plastic alternatives | Metal, carbon fibre, wood |
| Plastic alternatives properties | Metal: harder to work with, requires higher temperatures. Carbon fibre: extremely strong, lightweight, doesn't shrink when cooled. Wood: aesthetic, less brittle than PLA resin |
| Plastic printing processes | FDM, SLA, SLS |
| FDM process | Fused deposition modelling, or fused filament fabrication. Most widely used form of 3D printing. Melts and extrudes thermoplastic filaments layer by layer. Lowest resolution and accuracy. |
| SLA process | Stereolithography. First 3D printing technology. Uses a laser to cure thermosetting liquid resins into hardened plastic. Offers highest resolution and accuracy, clearest details, smoothest finish. |
| SLS process | Selective laser sintering. |
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What You'll Learn
- Acrylonitrile butadiene styrene (ABS) is the most common plastic used in 3D printing
- High-performance polymers are used in the automotive, aerospace and medical sectors
- Polyvinyl acetate (PVA) is used to create support structures for specific parts of a product that may otherwise warp or collapse
- Fused deposition modelling (FDM) is the most widely used form of 3D printing
- Stereolithography (SLA) offers the highest resolution and accuracy of all plastic 3D printing technologies
Acrylonitrile butadiene styrene (ABS) is the most common plastic used in 3D printing
ABS is commonly used in the form of filament, but it can also be found in powder form for powder bed processes such as SLS (Selective Laser Sintering). It has a printing temperature range of 230°C to 160°C and can withstand very low and high temperatures of -20°C and 80°C, respectively. ABS is ideal for general-purpose 3D printing, including prototypes and fixtures, but it can also be used in more demanding applications, such as maritime tooling and industrial production parts.
One of the unique properties of ABS is its ability to melt when heated at specific temperatures, cool, and be reheated without significant degradation. This property is due to its amorphous polymer structure, which means it does not have a true melting point but rather liquifies over a broad temperature range. To achieve the best results when printing with ABS, a fully enclosed print bed is recommended to maintain a higher internal temperature and avoid warping.
ABS is also available in resin form, making it suitable for SLA or material jetting processes. However, it is important to note that ABS is not biodegradable and can give off strong fumes during the 3D printing process. Therefore, a closed 3D build chamber is necessary to mitigate these emissions.
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High-performance polymers are used in the automotive, aerospace and medical sectors
3D printers use plastic because of its flexibility, impact resistance, and high strength. Acrylonitrile butadiene styrene (ABS) is the most commonly used plastic in the industry. It is widely used in car bodies, household appliances, and roofing applications.
High-performance polymers (HPPs) are used in the automotive, aerospace, and medical sectors due to their exceptional resistance to heat, chemicals, and stress. They are also significantly lighter than metals, which helps improve fuel efficiency and reduce carbon footprints. HPPs offer new performance capabilities by replacing metals in these industries.
In the automotive industry, polymers such as PEEK, PI, PAI, PEI, PFA, PSU, PESU, PPSU, PVDF, PPA, PPS, and LCP are considered for their functional capabilities, strength, durability, processability, and price. These polymers can be used to create car bodies and other automotive parts.
In the aerospace industry, HPPs are used for their high thermal stability and resistance to chemicals. They are also leveraged for their ability to reduce weight and increase fuel efficiency. Allegheny Performance Plastics, for example, has been producing high-temperature polymer parts for the commercial and defense aerospace industries for over 35 years.
In the medical sector, HPPs are used for their mechanical and thermal resistance, as well as their lightweight properties. They are often used in applications where durability and longevity are crucial.
Overall, the use of HPPs in these sectors offers new possibilities and enhances performance, making them a popular choice for demanding engineering applications.
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Polyvinyl acetate (PVA) is used to create support structures for specific parts of a product that may otherwise warp or collapse
Polyvinyl acetate (PVA) is a water-soluble synthetic polymer made by dissolving polyvinyl acetate in an alcohol, such as methanol, and treating it with an alkaline catalyst like sodium hydroxide. It is a colourless, non-toxic thermoplastic adhesive prepared by the polymerization of vinyl acetate. PVA is used in 3D printing to create support structures for specific parts of a product that may otherwise warp or collapse.
PVA is a versatile material with a wide range of applications. It is commonly used as a glue, thickener, or packaging film. In the context of 3D printing, PVA provides structural support to the product being printed, ensuring its stability and integrity during the manufacturing process. This is especially useful for complex designs with intricate details or parts that are susceptible to warping or collapsing without adequate support.
The solubility of PVA is a key advantage in 3D printing. After printing, the finished product can be soaked in water to dissolve the PVA-based support structure, leaving only the intended product. This solubility also makes PVA a popular choice for creating soluble filament materials in 3D printing. These soluble materials are printed with the intention of being dissolved at a later stage of the manufacturing process, allowing for intricate designs and temporary supports.
Additionally, PVA is used in combination with other materials to enhance their properties. For example, it is added to glass fibre-reinforced plastics to improve their stress and anti-shrink characteristics. PVA is also used in automobile headlights to enhance their gloss. In the construction industry, PVA is added to cement or concrete to improve their water resistance and bonding capabilities.
PVA is a valuable material in 3D printing due to its ability to provide temporary support structures, its solubility, and its enhancement of other materials' properties. Its versatility and unique characteristics make it a key component in the creation of complex and high-quality 3D-printed products.
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Fused deposition modelling (FDM) is the most widely used form of 3D printing
Fused Deposition Modelling (FDM) is the most popular form of 3D printing. FDM is an additive manufacturing (AM) process within the realm of material extrusion. FDM printers build parts layer by layer by selectively depositing melted material in a predetermined path. FDM uses thermoplastic polymers that come in filaments to form the final physical objects.
FDM is the most widely used technology across most industries and is likely the first process people think of when it comes to 3D printing. FDM's broad material portfolio addresses a wide spectrum of applications, from functional prototyping to end-use parts. FDM technology is trusted for its precision, reliability, repeatability, and ease of use. With printers that are suitable for an office setting, as well as industrial-grade platforms for the factory floor, it is one of the easiest 3D printing technologies to learn and operate.
FDM's versatility and sizeable material selection make it a go-to resource for all major industries that need time and cost-efficient alternatives to traditional manufacturing. FDM technology can be used with a wide range of materials, including commodity thermoplastics such as PLA, ABS, TPU, PETG, and PEI. Producing custom parts with FDM is relatively quick, with short lead times (typically only a few days).
FDM printers can also be used with high-performance polymers, which are very strong but much lighter than metals. For this reason, they are very popular in the aerospace, automotive, and medical sectors. However, high-performance polymers can't be printed on all 3D printers; they require a heating plate capable of reaching at least 230°C, an extrusion of 350°C, and a closed chamber.
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Stereolithography (SLA) offers the highest resolution and accuracy of all plastic 3D printing technologies
Stereolithography, or SLA, is the first commercialised 3D printing technology, invented in the 1980s. SLA offers the highest resolution and accuracy of all plastic 3D printing technologies. SLA technology is extremely versatile and can be used in any number of areas where precision is paramount. SLA also offers a speed advantage when you require a variety of functional prototypes or quick access to casting patterns. SLA’s combination of speed and precision make it an excellent choice for evaluating prototypes. The accuracy of SLA means your prints are faithful to the final design, allowing you to identify and correct design flaws, collisions, and potential mass-manufacturing issues before production begins. SLA also allows for reduced material costs, as any unused resin can be reused for future projects.
SLA technology uses an ultraviolet laser to precisely cure photopolymer cross-sections, transforming them from liquid to solid. SLA printers build parts directly from 3D CAD data without tooling by converting liquid materials and composites into solid cross-sections, layer by layer. SLA is an additive manufacturing process where a light source cures liquid resin into hardened plastic. SLA 3D printed parts are being used in every industry as end-use products, industrial replacement parts, manufacturing aids, tooling, and more. SLA offers the widest range of material options for plastic 3D printing, with resins that can be soft or hard, filled with secondary materials, or imbued with mechanical properties.
SLA's high resolution and accuracy are further enhanced by its low printing temperature, as the process uses light instead of heat. This means that printed parts don't suffer from thermal expansion and contraction. SLA printers can create hyper-accurate cross-sections of each part, and resin 3D printers create parts with a smooth surface finish, which means barely any visible layer lines, even on complex features like curved edges. The tolerances on SLA parts are typically less than 0.05 mm, and SLA offers the smoothest surface finish of any additive manufacturing process.
SLA is an excellent choice for creating highly precise casting patterns, and it is particularly useful for injection moulding and casting. SLA technology is also useful for quick interchangeable material delivery modules, and it is often used when form, fit, and assembly are critical.
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Frequently asked questions
Plastic is the most popular 3D-printing material because it is strong, flexible, impact-resistant, and lighter than metals. It is also widely available and has a low printing temperature of 230°C-160°C.
The most common plastics used in 3D printing are Acrylonitrile Butadiene Styrene (ABS), Polyvinyl Acetate (PVA), High Impact Polystyrene (HIPS), and Polylactic Acid (PLA).
ABS plastic is strong, flexible, impact-resistant, and can tolerate very low and very high temperatures. It also has a polished surface, is reusable, and can be welded by chemical processes.
ABS plastic is not biodegradable and shrinks in contact with air, so a heated build platform is required during printing. It also releases fumes during the printing process, so a controlled environment is necessary.
