3D printing offers a revolutionary approach to prototyping and manufacturing, enabling the rapid and cost-effective creation of parts for diverse applications. However, selecting the appropriate 3D printing process is only part of the equation. The choice of 3d Printer Materials is equally crucial, as it ultimately dictates the mechanical properties, functional characteristics, and aesthetic qualities of the final product.
This guide provides an in-depth exploration of the most popular plastic and metal 3D printer materials currently available. We will compare their properties, discuss typical applications, and present a structured framework to assist you in selecting the ideal material for your specific project needs.
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Unsure about which 3D printing material best suits your project? Our interactive material catalog is designed to guide you. It helps you navigate our extensive library of 3D printing materials and make informed decisions based on your application and the material properties that matter most to you.
Plastic 3D Printing Materials and Processes
The world of plastic 3D printer materials is vast and varied, with numerous options each tailored to specific applications. To simplify your material selection process, we will first categorize the main types of plastics and then explore the common 3D printing processes used with them.
Types of Plastic Materials
Fundamentally, plastics fall into two primary categories:
- Thermoplastics: These are the most widely used plastics in 3D printing. Their defining characteristic is their ability to repeatedly melt and solidify without significant degradation. Thermoplastics can be heated, shaped, and then reheated and reshaped, making the process reversible. This property also makes them recyclable and reusable. A helpful analogy is butter: it can be melted, solidified, and melted again, though its properties may subtly change with each cycle.
- Thermosetting Plastics (Thermosets): Thermosets, in contrast, undergo an irreversible chemical change during curing. This curing process, often initiated by heat, light, or radiation, creates cross-links within the polymer structure, resulting in a permanently solid material. Once cured, thermosets decompose when heated rather than melting, and they cannot be reformed. Think of cake batter: once baked into a cake, it cannot be melted back into batter. Recycling thermosets back to their original components is generally not feasible.
Plastic 3D Printing Processes
Three dominant plastic 3D printing processes are prevalent today:
- Fused Deposition Modeling (FDM): FDM 3D printers work by melting thermoplastic filaments and extruding them through a nozzle. This nozzle precisely deposits the molten material layer by layer onto the build platform, creating the 3D object.
- Stereolithography (SLA): SLA 3D printers utilize a laser to selectively cure thermosetting liquid resins. This process, known as photopolymerization, hardens the resin layer by layer, forming the 3D part.
- Selective Laser Sintering (SLS): SLS 3D printers employ a high-powered laser to fuse together small particles of thermoplastic powder. The laser selectively sinters the powder layer by layer, building the object within a powder bed.
Video Guide
How to Choose a 3D Printing Technology
Struggling to determine the best plastic 3D printer for your needs? This video guide offers a comparative analysis of FDM, SLA, and SLS technologies, considering key factors in your purchasing decision.
FDM 3D Printing
Fused Deposition Modeling (FDM), also known as Fused Filament Fabrication (FFF), stands as the most widespread 3D printing method, particularly at the consumer level, largely due to the accessibility of hobbyist 3D printers.
FDM excels in producing basic proof-of-concept models and rapid, low-cost prototypes of simpler parts, often serving as an alternative to traditional machining for certain components.
However, consumer-grade FDM typically offers lower resolution and accuracy compared to other plastic 3D printing processes. It may not be ideal for intricate designs or parts with fine details. Post-processing techniques like chemical and mechanical polishing can improve surface finish. Industrial FDM 3D printers, which utilize soluble supports and a broader range of engineering thermoplastics and composites, can mitigate some limitations, but come at a higher cost.
A characteristic of FDM is the potential for voids between layers due to incomplete layer adhesion. This can result in anisotropic parts, meaning their properties vary depending on the direction of stress. This anisotropy is an important consideration when designing load-bearing parts.
FDM 3D printing materials are available in a diverse spectrum of colors. Furthermore, innovative plastic filament blends are emerging, capable of creating parts with textures resembling wood or metal.
Popular FDM 3D Printing Materials
The most commonly used FDM 3D printing materials are ABS, PLA, and their numerous blends. More advanced FDM printers can also handle specialized materials offering enhanced properties such as heat resistance, impact resistance, chemical resistance, and rigidity.
| Material | Features | Applications |
|---|---|---|
| ABS (Acrylonitrile Butadiene Styrene) | Tough and durable, Heat and impact resistant, Requires heated bed, Ventilation recommended | Functional prototypes |
| PLA (Polylactic Acid) | Easiest FDM material to print, Rigid, strong but brittle, Lower heat and chemical resistance, Biodegradable, Odorless | Concept models, Looks-like prototypes |
| PETG (Polyethylene Terephthalate Glycol) | Lower printing temperatures for faster production, Humidity and chemical resistant, High transparency, Food safe options | Waterproof applications, Snap-fit components |
| Nylon | Strong, durable, and lightweight, Tough and semi-flexible, Heat and impact resistant, More complex to print with 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, Water-soluble | Support material |
| HIPS (High Impact Polystyrene) | Soluble support material (for ABS), Dissolves in limonene | Support material |
| Composites (Carbon Fiber, Kevlar, Fiberglass) | Rigid, strong, or extremely tough, Compatibility limited to industrial FDM printers | Functional prototypes, Jigs, fixtures, and tooling |
SLA 3D Printing
Stereolithography holds the distinction of being the first 3D printing technology, developed in the 1980s. It remains a leading technology for professionals seeking high precision and surface quality.
SLA produces parts with the highest resolution, accuracy, finest details, and smoothest surface finish among plastic 3D printing technologies. Resin 3D printing is ideally suited for detailed prototypes demanding tight tolerances and smooth surfaces, as well as functional components like molds, patterns, and end-use parts. SLA 3D printed parts are also amenable to various post-processing methods such as polishing, painting, and coating, resulting in client-ready parts with premium finishes.
SLA printed parts exhibit isotropy – consistent strength regardless of orientation. This is due to the chemical bonds that form between layers during the printing process, leading to predictable mechanical performance crucial for applications like jigs and fixtures, end-use parts, and functional prototyping.
SLA offers the most extensive selection of material options for plastic 3D printing.
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Guide to Stereolithography (SLA) 3D Printing
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Popular SLA 3D Printing Materials
SLA 3D printing boasts remarkable versatility, offering resin formulations that mimic the properties of standard, engineering, and industrial thermoplastics across optical, mechanical, and thermal characteristics. Resin 3D printing also provides the broadest range of biocompatible materials.
Material availability is printer and manufacturer dependent. Formlabs stands out with the most comprehensive resin library, offering over 40 SLA 3D printing materials.
| Formlabs Materials | Features | Applications |
|---|---|---|
| Standard Resins | High resolution, Smooth, matte surface finish | Concept models, Looks-like prototypes |
| Clear Resin | Truly clear plastic 3D printing material, Polishes to optical transparency | Transparent parts, Millifluidics |
| Draft Resin | Fastest 3D printing material option, 4x faster than standard resins, Up to 10x faster than FDM | Initial prototypes, Rapid iterations |
| Tough and Durable Resins | Strong, robust, functional, dynamic, Withstands compression, stretching, bending, impacts, Properties similar to ABS or PE | Housings, enclosures, Jigs, fixtures, Connectors, Wear-and-tear prototypes |
| Rigid Resins | Highly filled, strong, stiff, Bending resistant, Thermally and chemically resistant, Dimensionally stable under load | Jigs, fixtures, tooling, Turbines, fan blades, Fluid, airflow components, Electrical casings, automotive housings |
| Polyurethane Resins | Excellent long-term durability, UV, temperature, humidity stable, Flame retardancy, sterilizability, chemical and abrasion resistance | High-performance automotive, aerospace, machinery components, Robust end-use parts, Tough, longer-lasting functional prototypes |
| High Temp Resin | High temperature resistance, High precision | Hot air, gas, fluid flow applications, Heat resistant mounts, housings, fixtures, Molds, inserts |
| Flexible and Elastic Resins | Rubber, TPU, or silicone-like flexibility, Bending, flexing, compression capable, Resists repeated cycles without tearing | Consumer goods prototyping, Compliant robotics features, Medical devices, anatomical models, Special effects props, models |
| Silicone 40A Resin | First accessible 100% silicone 3D printing material, Superior cast silicone properties | Functional prototypes, validation units, small silicone part batches, Customized medical devices, Flexible fixtures, masking tools, soft urethane/resin casting molds |
| Medical and Dental Resins | Wide range of biocompatible resins for medical and dental appliances | Dental and medical appliances: surgical guides, dentures, prosthetics |
| Jewelry Resins | Investment casting and vulcanized rubber molding materials, Easy to cast, intricate details, strong shape retention | Try-on pieces, Masters for reusable molds, Custom jewelry |
| ESD Resin | ESD-safe material for electronics manufacturing workflows | Tooling & fixturing for electronics manufacturing, Anti-static prototypes, end-use components, Custom trays for component handling, storage |
| Flame Retardant (FR) Resin | Flame retardant, heat-resistant, stiff, creep-resistant, For indoor, industrial environments with high temperatures/ignition sources | Airplane, automobile, railway interior parts, Custom industrial jigs, fixtures, replacement parts, Protective, internal consumer/medical electronics components |
| Alumina 4N Resin | 99.99% pure alumina technical ceramic, Exceptional thermal, mechanical, conductive properties | Heat, electrical insulators, Heavy-duty tools, Chemically resistant, wear-resistant components |
Explore Formlabs SLA Materials
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SLS 3D Printing
Selective Laser Sintering (SLS) 3D printing is trusted across industries by engineers and manufacturers for producing strong, functional parts. Its low per-part cost, high productivity, and established materials make it suitable for applications ranging from rapid prototyping to manufacturing aids, and low-volume, bridge, or custom manufacturing.
The unfused powder bed in SLS acts as support during printing, eliminating the need for dedicated support structures. This advantage makes SLS ideal for complex geometries, including internal features, undercuts, thin walls, and negative features.
Similar to SLA, SLS 3D prints are generally isotropic. SLS parts have a slightly rougher surface finish due to powder particles but exhibit minimal visible layer lines. SLS 3D prints are readily post-processed to enhance mechanical performance and appearance further.
SLS 3D printing materials excel in functional applications, from engineering consumer products to manufacturing and healthcare.
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Introduction to Selective Laser Sintering (SLS) 3D Printing
Looking for a 3D printer to create robust, functional parts? Download our white paper to learn about SLS printing, a popular 3D printing process for functional prototyping and end-use production.
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Popular SLS 3D Printing Materials
The material selection for SLS is more limited compared to FDM and SLA, but the available materials possess excellent mechanical properties, often resembling injection-molded parts in strength. Nylon is the most common material for selective laser sintering, a popular engineering thermoplastic known for its mechanical properties: lightweight, strong, flexible, and stable against impact, chemicals, heat, UV light, water, and dirt. Other popular SLS 3D printing materials include polypropylene (PP) and flexible TPU.
| Material | Description | Applications |
|---|---|---|
| Nylon 12 | Strong, stiff, sturdy, durable, Impact-resistant, withstands wear and tear, UV, light, heat, moisture, solvent, temperature, and water resistant | Functional prototyping, End-use parts, Medical devices |
| Nylon 11 | Similar to Nylon 12 properties, higher elasticity, elongation at break, impact resistance, lower stiffness | Functional prototyping, End-use parts, Medical devices |
| Nylon Composites | Nylon reinforced with glass, aluminum, or carbon fiber for added strength and rigidity | Functional prototyping, Structural end-use parts |
| Polypropylene | Ductile, durable, Chemically resistant, Watertight, Weldable | Functional prototyping, End-use parts, Medical devices |
| TPU | Flexible, elastic, rubbery, Deformation resilient, High UV stability, Shock absorption | Functional prototyping, Flexible, rubber-like end-use parts, Medical devices |
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Compare Plastic 3D Printing Materials and Processes
Different 3D printing materials and plastic 3D printing processes offer distinct advantages and disadvantages, influencing their suitability for various applications. The table below summarizes key characteristics and considerations.
| FDM | SLA | SLS |
|---|---|---|
| Pros | Low-cost consumer machines and materials, Widely accessible | Great value, High accuracy, Smooth surface finish, Range of functional materials |
| Cons | Lower accuracy, Limited detail, Design constraints, Higher cost for industrial machines with accuracy and high-performance materials | Sensitive to prolonged UV exposure |
| Applications | Low-cost rapid prototyping, Basic proof-of-concept models, Select end-use parts (industrial machines/materials) | Functional prototyping, Patterns, molds, tooling, Dental applications, Jewelry prototyping, casting, Models, props |
| Materials | Standard thermoplastics (ABS, PLA, blends) on consumer machines, High-performance composites on industrial machines | Variety of resins (thermosets): standard, engineering (ABS-like, PP-like, flexible, heat-resistant), castable, dental, medical (biocompatible), Pure silicone, ceramic |
Compare FDM vs. SLA vs. SLS 3D Printing Processes
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Metal 3D Printing
Beyond plastics, several 3D printing processes cater to metal 3D printer materials.
-
Metal FDM:
Metal FDM printers function similarly to traditional FDM printers, but extrude metal rods held together by polymer binders. After printing, the “green” parts undergo sintering in a furnace to remove the binder and fuse the metal particles. -
Selective Laser Melting (SLM) and Direct Metal Laser Sintering (DMLS):
SLM and DMLS metal 3D printers operate like SLS printers, but fuse metal powder particles using a laser instead of polymer powders. These processes create strong, accurate, complex metal products suitable for aerospace, automotive, and medical industries.
Popular Metal 3D Printing Materials
- Titanium: Lightweight with excellent mechanical properties: strong, hard, heat, oxidation, and acid resistant.
- Stainless Steel: High strength, ductility, and corrosion resistance.
- Aluminum: Lightweight, durable, strong, with good thermal properties.
- Tool Steel: Hard, scratch-resistant, for end-use tools and high-strength parts.
- Nickel Alloys: High tensile, creep, rupture strength, heat and corrosion resistant.
Alternatives to Metal 3D Printing
Compared to plastic 3D printers, metal 3D printing is significantly more expensive and complex, limiting accessibility for many businesses.
Alternatively, SLA 3D printing is well-suited for casting workflows to produce metal parts at lower cost, with greater design freedom, and faster turnaround than traditional methods.
Another alternative is electroplating SLA parts, coating plastic with a metal layer via electrolysis. This combines metal’s strength, electrical conductivity, and corrosion/abrasion resistance with the base plastic material’s specific properties.
Plastic 3D printing is effective for creating patterns for metal part casting.
Framework for Choosing the Right Plastic 3D Printing Material
With a wide array of materials and 3D printing options, a structured approach is essential for making the right choice.
Here’s a three-step framework to guide you in selecting the ideal 3D printing material and plastic 3D printer for your application.
Step 1: Define Performance Requirements
3D printing plastics exhibit diverse chemical, optical, mechanical, and thermal characteristics that dictate part performance. As the intended application approaches real-world use, performance demands increase.
| Requirement | Description | Recommendation |
|---|---|---|
| Low Performance | Form/fit prototyping, conceptual modeling, R&D, minimal technical demands. Example: Ergonomic soup ladle prototype (form testing), surface finish only requirement. | FDM: PLA, SLA: Standard Resins, Clear Resin (transparent), Draft Resin (fast) |
| Moderate Performance | Validation/pre-production, parts mimic final production parts for functional testing, limited lifetime needs. Example: Electronic component housing (impact protection), impact absorption, snap-fit, shape retention needed. | FDM: ABS, SLA: Engineering Resins, SLS: Nylon 11, nylon 12, polypropylene, TPU |
| High Performance | End-use parts, final 3D printed production parts withstand significant wear over time (days, weeks, years). Example: Shoe outsoles, strict lifetime testing (cyclic loading), color fastness (years), tear resistance. | FDM: Composites, SLA: Engineering, Medical, Dental, Jewelry Resins, SLS: Nylon 12, nylon 11, nylon composites, polypropylene, TPU |
Step 2: Translate Performance Requirements to Material Requirements
After defining performance needs, translate them into material requirements – the specific properties needed to meet those demands. Material data sheets provide these crucial metrics.
| Requirement | Description | Recommendation |
|---|---|---|
| Tensile Strength | Material’s resistance to breaking under tension. High tensile strength for structural, load-bearing, mechanical, static parts. | FDM: PLA, SLA: Clear Resin, Rigid Resins, Alumina 4N Resin, SLS: Nylon 12, nylon composites |
| Flexural Modulus | Material’s bending resistance under load. Indicates stiffness (high modulus) or flexibility (low modulus). | FDM: PLA (high), ABS (medium), SLA: Rigid Resins (high), Tough and Durable Resins (medium), Flexible and Elastic Resins (low), SLS: Nylon composites (high), nylon 12 (medium) |
| Elongation | Material’s resistance to breaking when stretched. Compares flexible materials’ stretchability, indicates deformation vs. sudden breakage. | FDM: ABS (medium), TPU (high), SLA: Tough and Durable Resins (medium), Polyurethane Resins (medium), Flexible and Elastic Resins (high), Silicone 40A Resin (high), SLS: Nylon 12 (medium), nylon 11 (medium), polypropylene (medium), TPU (high) |
| Impact Strength | Material’s ability to absorb shock/impact energy without breaking. Indicates toughness, durability, breakage susceptibility from drops/impacts. | FDM: ABS, Nylon, SLA: Tough 2000 Resin, Tough 1500 Resin, Grey Pro Resin, Durable Resin, Polyurethane Resins, SLS: Nylon 12, nylon 11, polypropylene, nylon composites |
| Heat Deflection Temperature | Temperature at which material deforms under load. Indicates suitability for high-temperature applications. | SLA: High Temp Resin, Rigid Resins, Alumina 4N Resin, SLS: Nylon 12, Nylon 11, nylon composites |
| Hardness (Durometer) | Material’s surface deformation resistance. Identifies “softness” for soft plastics, rubber, elastomers. | FDM: TPU, SLA: Flexible Resin, Elastic Resin, Silicone 40A Resin, SLS: TPU |
| Tear Strength | Material’s resistance to cut growth under tension. Assesses durability, tear resistance of soft plastics, flexible materials, rubber. | FDM: TPU, SLA: Flexible Resin, Elastic Resin, Silicone 40A Resin, SLS: TPU |
| Creep | Material’s tendency to permanently deform under constant stress (tensile, compressive, shear, flexural). Low creep indicates longevity for structural hard plastics. | FDM: ABS, SLA: Polyurethane Resins, Rigid Resins, Alumina 4N Resin, SLS: Nylon 12, nylon 11, nylon composites, polypropylene |
| Compression Set | Permanent deformation after compression. Important for soft plastics, elastic applications, indicates shape recovery after load removal. | FDM: TPU, SLA: Flexible Resin, Elastic Resin, Silicone 40A Resin, SLS: TPU |
For deeper insights into material properties, consult our guide to common mechanical and thermal properties.
Step 3: Make a Selection
Translating performance needs to material requirements narrows down material choices. If multiple suitable materials remain, consider desired characteristics, pros, cons, and trade-offs to finalize your selection.
Find the Best 3D Printing Material for Your Project
Utilize our interactive material wizard to discover materials based on your application and prioritized properties within Formlabs’ material library. For specific 3D printing material questions, contact our 3D printing experts.
