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Guide to 3D Printing:Materials, Types, Applications, and Properties

29-06-2024

Guide to FDM 3D Printing:

Materials, Types, Applications, and Properties




There are dozens of plastic materials available for 3D printing, each with their own unique qualities that make them best suited for specific uses. To simplify the process of finding the best material for a particular part or product, lets first take a look at the main types of plastics and the different 3D printing processes.

 

Types of Plastic Materials

There are two main types of plastics:

 

Thermoplastics are the most commonly used type of plastic. Their main difference from thermosets is their ability to undergo multiple cycles of melting and solidification. Thermoplastics can be heated and formed into a desired shape. The process is reversible, as no chemical bonding occurs, so thermoplastics can be recycled, melted, and reused. A common analogy for thermoplastics is butter, which can be melted, resolidified, and melted again. Its properties change slightly during each melting cycle.

 

Thermosets (also known as thermosetting plastics) remain in a permanent solid state after curing. The polymers in thermosets crosslink during the curing process, which is caused by heat, light, or suitable radiation. Thermosets decompose when heated rather than melting, and do not reform when cooled. It is impossible to recycle thermosets or return the material to its basic components. Thermosets are like cake batter, and once baked into the cake, they cannot be melted back into the batter.

 

Plastic 3D Printing Processes

The three most established plastic 3D printing processes are as follows:

 

Fused Deposition Modeling (FDM) 3D printers melt and extrude thermoplastic filament, which is deposited layer by layer on the build area by the printer nozzle.

 

Stereolithography (SLA) 3D printers use lasers to cure thermosetting liquid resins into hardened plastics, a process called photopolymerization.

 

Selective Laser Sintering (SLS) 3D printers use high-powered lasers to melt small particles of thermoplastic powder.


FDM 3D Printing

Fused deposition modeling (FDM), also known as fused filament fabrication (FFF), is the most widely used form of 3D printing at the consumer level, fueled by the emergence of hobbyist 3D printers.

 

This technique is well-suited for basic proof-of-concept models, as well as quick and low-cost prototyping of simple parts, such as parts that might typically be machined.

 

Consumer level FDM has the lowest resolution and accuracy when compared to other plastic 3D printing processes and is not the best option for printing complex designs or parts with intricate features. Higher-quality finishes may be obtained through chemical and mechanical polishing processes. Industrial FDM 3D printers use soluble supports to mitigate some of these issues and offer a wider range of engineering thermoplastics or even composites, but they also come at a steep price.

 

As the melted filament forms each layer, sometimes voids can remain between layers when they dont adhere fully. This results in anisotropic parts, which is important to consider when you are designing parts meant to bear load or resist pulling.


3d printing


FDM 3D printing materials are available in a variety of color options. Various experimental plastic filament blends also exist to create parts with wood- or metal-like surfaces.

 

Popular FDM 3D Printing Materials

The most common FDM 3D printing materials are ABS, PLA, and their various blends. More advanced FDM printers can also print with other specialized materials that offer properties like higher heat resistance, impact resistance, chemical resistance, and rigidity.

MATERIAL

FEATURES

APPLICATIONS

ABS (acrylonitrile butadiene styrene)

Tough and durable
Heat and impact resistant
Requires a heated bed to print
Requires ventilation

Functional prototypes

PLA (polylactic acid)

The easiest FDM materials to print
Rigid, strong, but brittle
Less resistant to heat and chemicals
Biodegradable
Odorless

Concept models
Looks-like prototypes

PETG (polyethylene terephthalate glycol)

Compatible with lower printing temperatures for faster production
Humidity and chemical resistant
High transparency
Can be food safe

Waterproof applications
Snap-fit components

Nylon

Strong, durable, and lightweight
Tough and partially flexible
Heat and impact resistant
Very complex to print on FDM

Functional prototypes
Wear resistant parts

TPU (thermoplastic polyurethane)

Flexible and stretchable
Impact resistant
Excellent vibration dampening

Flexible prototypes

PVA (polyvinyl alcohol)

Soluble support material
Dissolves in water

Support material

HIPS (high impact polystyrene)

Soluble support material most commonly used with ABS
Dissolves in chemical limonene

Support material

Composites (carbon fiber, kevlar, fiberglass)

Rigid, strong, or extremely tough
Compatibility limited to some expensive industrial FDM 3D printers

Functional prototypes
Jigs, fixtures, and tooling

 

 

 

 

 






 


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