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Picking the right material for your 3D print job

 

Know your printer.

The initial step in selecting the appropriate material for your 3D printing project is understanding the capabilities of your printer. Different types of 3D printers utilize distinct methods and materials for fabricating objects, such as fused deposition modelling (FDM), stereolithography (SLA), or selective laser sintering (SLS). Each printer comes with its own set of specifications, constraints, and compatibility with specific materials.

For instance, FDM printers are compatible with thermoplastics like ABS or PLA, whereas SLA printers can handle photopolymers such as resin. To determine which materials your printer supports and how to use them correctly, refer to its manual or website for guidance.

 

Consider your purpose.

The following step in selecting the appropriate material for your 3D printing project is to consider the objectives you aim to achieve. What is the intended purpose, function, and visual appeal of your 3D printed item? Depending on your aspirations, you may require materials with varying properties and characteristics.

For instance, if you intend to print a functional component that must endure high temperatures, stress, or abrasion, materials like nylon or polycarbonate might be suitable choices. Conversely, if you aim to create a decorative or artistic piece featuring intricate details, smooth surfaces, or translucent effects, materials such as resin or wood may be more appropriate.

 

Compare your options.

The final step in selecting the appropriate material for your 3D printing project involves comparing your options and carefully considering the pros and cons of each material. Various factors come into play during this decision-making process, including cost, availability, printability, durability, flexibility, strength, weight, colour, texture, and finish.

Some materials may be more costly, rare, or challenging to print, while others offer greater durability, flexibility, or strength. Additionally, certain materials provide a wider range of colour, texture, or finish options compared to others. It's essential to strike a balance among these factors to identify the best material for your budget, preferences, and project requirements.

Choosing the right material for your 3D printing endeavour can be challenging, but it significantly influences the outcome of your project. By following these three steps, you can narrow down your choices and find the ideal material for your specific needs. Remember to conduct tests with your chosen material before embarking on large or intricate prints, and always adhere to the best practices and safety guidelines for your printer and material. Happy printing!

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Filaments (FDM) Printing Information

 

PLA ( Polylactide)

For those venturing into the realm of 3D printing, PLA stands out as a convenient choice. It's user-friendly, boasting easy printing at lower temperatures and eliminating the need for heated beds or controlled build environments. Additionally, PLA filament is readily available at an affordable price point.

However, it's essential to acknowledge PLA's limitations alongside its benefits. While it suits beginners and less demanding projects admirably, it lacks the heat resistance and robustness found in alternative 3D printing materials. Therefore, when durability and mechanical strength are paramount, PLA may not suffice.

In contrast, silk PLA filament emerges as a standout option for those seeking exceptional results in their 3D printing endeavors. With its distinctive matte finish and silky texture, it elevates the aesthetics of printed objects, appealing to both seasoned designers and hobbyists alike. Despite its higher cost compared to traditional PLA, the visual and tactile enhancements it brings to creations justify the investment.

In essence, while PLA serves as an accessible entry point into 3D printing, silk PLA filament offers a notable upgrade, enabling the production of remarkable, standout pieces. So, for those eager to explore the full potential of 3D printing and craft truly impressive creations, embracing silk PLA filament is a decision worth considering.

 

PETG ( glycol-modified polyethylene terephthalate)

PETG stands for glycol-modified polyethylene terephthalate – similar to PET, which you may know from plastic water bottles – but an additional glycol is included in the polymer structure, hence the letter “G” after PET for “glycol-modified”. The result is a clearer, less temperature-sensitive material that’s easier to extrude than PET. However, it does have the unfortunate side effect of changing the recycling process. Although PET is widely recycled, PETG is not; the subtle differences between these materials create a troublesome contaminant in recycling facilities.

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Still, it’s an excellent filament choice for printing objects that need to be sturdy, smooth, and exhibit low shrinkage. It’s also popular because PETG is considered food safe, but you should still read the fine print on any spool you buy to be sure.

Of course, it’s not all good news: PETG isn’t great at bridging because it’s super sticky. However, this does mean it has great layer adhesion. It’s also more prone to both heavy stringing and air-moisture absorption. But still, if you need a high-strength material and PLA or ABS just won’t cut it, standard PETG is a great option. Though PETG is perhaps the best known in its family of filaments, it’s a variant of PET plastic – an exceedingly common material often found in water bottles and other single-use plastics. There are more variations of PET in filament than just the familiar glycol-added version, and all of them share many properties but with some important differences.

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PET: Polyethylene terephthalate (PET) is one of the most commonly used plastics in the world and the unmodified parent of PETG. It melts at 260 °C and has the most potential for recycling – local programme permitting. PET struggles more with layer adhesion compared to PETG. rPET: Exactly the same as its base material, PET, but this filament gets a lowercase “r” in its name because it’s made from recycled PET. Previously recycled materials may not be recyclable again, at least not with the same results. CPE: Some brands choose to differentiate PET products with a moniker. Fillamentum and UltiMaker use “CPE” because it stands for copolyester. PETT: Polyethylene co-trimethylene terephthalate is slightly more rigid than PETG because it isn’t modified with glycol. It isn’t very common in 3D printing but was popularised by Taulman T-Glase.

 

ASA (acrylonitrile styrene acrylate) 

Acrylonitrile styrene acrylate, also known as ASA, is an engineering thermoplastic with a similar molecular structure to the very popular and commonly used acrylonitrile butadiene styrene, also known as ABS. ASA is recognised for its high impact resistance and good chemical resilience. It can withstand high temperatures (softening at 105°C) and exhibits excellent dimensional stability.

In comparison to ABS, ASA boasts UV stability and maintains its appearance and resistance even after prolonged exposure to sunlight and water. It finds applications in various common products, including automotive parts (such as bumper covers and side mirror housings), gutter and drain pipes, and outdoor furniture.

In the All3DP office, we have had positive experiences producing functional ASA parts using popular desktop printers like the Original Prusa MK4 and the Creality K1. The built-in enclosure of the K1 proved particularly advantageous in mitigating some of the typical challenges associated with ASA printing.

In the following sections, we will examine the advantages and disadvantages of ASA before delving into the requirements for printing with this material, addressing both hardware and software considerations.

 

ABS (acrylonitrile styrene acrylate)

ABS (acrylonitrile butadiene styrene) is perhaps the most prevalent filament utilised in 3D printing, particularly valued for producing robust plastic parts capable of withstanding temperature fluctuations. Primarily employed in FDM (fused deposition modelling) 3D printers, ABS is a thermoplastic polymer comprising three monomers: acrylonitrile, butadiene, and styrene. Initially patented in the 1940s, ABS rapidly gained popularity.

Today, ABS finds extensive application across various industries owing to its flexibility, mouldability, and strength. Its versatility is evidenced by its presence in diverse products such as Lego toys, household appliances, and piping systems. Compared to many budget-friendly polymers, ABS exhibits considerable flexibility, resistance to high temperatures, and ease of machining. Within the realm of 3D printing, ABS is highly prized for its swift printing capabilities and superior durability. This article aims to elucidate ABS 3D printing filament, scrutinise its composition and characteristics, and juxtapose it with other 3D printing filaments. ABS stands among the array of polymer filaments compatible with FDM and FFF printers, easily malleable into virtually any desired shape at the appropriate temperature. Notably, ABS solidifies uniformly and requires no post-processing. Users typically opt for it due to its relatively high-temperature resilience and flexibility.

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CARBON FIBRE

Carbon fibre filaments utilise minuscule fibres infused into a base material to enhance its properties. Various popular filaments are available with carbon fibre fill, including PLA, PETG, Nylon, ABS, and Polycarbonate. These fibres exhibit exceptional strength, augmenting the filament's overall strength and rigidity. Consequently, 3D printed parts become notably lighter and more dimensionally stable, as the fibres mitigate part shrinkage during cooling. Print settings, such as temperature, speed, bed adhesion, and extrusion rates, will closely resemble those used for the base material to which the fibres were added (for instance, default PLA settings serve as a suitable starting point for PLA-based carbon fibre filament). Nonetheless, owing to the additional fibres, these specialised materials are more prone to nozzle clogging and may necessitate specialised hardware to safeguard the printer from damage.

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SUPPORT

Support material is a low-density structure created by a 3D printer to support overhanging or undercutting sections in a model. It is designed for easy removal post-production. The UP software provided with UP 3D printers automatically calculates and generates the necessary support based on user settings. On printers like the UP Mini, UP Plus, and UP+2, support material is made from the same filament or material chosen for the model, ensuring compatibility and eliminating the need to switch materials mid-print. For printers like the Inspire range with dual extruders, soluble support material can be simultaneously created, offering the advantage of dissolving support material in tight or delicate areas without risking damage to the object. Support material is essential for models with angles, providing a foundation for printing. Even objects with angles greater than 10° benefit from support material, ensuring smoother underside surfaces.

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POLYCARBONATE (PC)

Polycarbonate (PC) is a versatile material in 3D printing, prized for its durability, heat tolerance, and resistance to chemicals, provided certain guidelines are followed. It serves as an excellent thermoplastic choice for manufacturing mechanical components, molds (especially those used in thermoforming), functional prototypes, hinges, and even pulley bearings. PC is often blended with other plastics to enhance its impact resistance, as seen in alloys like PC-ABS, which finds use in products such as drone bodies and replacement parts requiring superior durability compared to ABS alone.

Successful 3D printing with polycarbonate necessitates a printer capable of accommodating its properties. Essential features include a nozzle capable of reaching temperatures around 300 ºC, an enclosed printing chamber, and a robust temperature control system. These components increase the likelihood of achieving satisfactory prints and ensure the material's unique requirements are effectively met.

In this article, we delve deeper into polycarbonate 3D printing, covering its definition, functionality, advantages and disadvantages, and providing examples of applications.

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Thermoplastic polyurethane (TPU)

Thermoplastic polyurethane (TPU) is an elastomer, or synthetic plastic, prized for its exceptional flexibility and resistance during further processing. It combines the properties of thermoplastics and elastomers, boasting significantly higher compressive and tensile forces compared to common materials like PLA and ABS. The material's softness and hardness can vary depending on its chemical composition, with the proportion of hard and soft segments dictating its flexibility. A lower filling quantity can result in a more flexible 3D-printed part, impacting factors such as transparency, softness to the touch, and part adhesion. TPU is highly versatile, endowing parts with a diverse range of properties. Additionally, TPU offers superior resistance to greases and oils. When using TPU, considerations include understanding its chemical composition's influence on flexibility, adjusting filling quantity for desired flexibility, and accounting for its resistance to greases and oils.​

Stereolithography (SLA) Resin Printing Information

The Best 3D Printing Resins

The best resin types for 3D printing vary depending on the specific application. Generally, the most popular resin types are ABS, PLA, PETG, nylon, polycarbonate, and resin. Each resin type possesses unique properties that render it suitable for different applications. Resin performance is contingent upon the printer in use and the object being printed.

The proliferation of industrial, commercial, and consumer resin 3D printers has facilitated the expansion of the resin industry. Standard resins are readily available for dental, engineering, ceramic, jewelry, and other unique applications. In general, the most popular resins for 3D printing are:

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ABS – ABS resin, or Acrylonitrile Butadiene Styrene, is a thermoplastic polymer commonly utilized in the fabrication of consumer products like toys, appliances, automotive parts, and electronic components. It boasts a lightweight yet rigid nature and exhibits resistance to chemicals, abrasions, and impacts.

However, ABS does present certain concerns, including shrinkage, thermal expansion, limited chemical resistance, susceptibility to UV degradation, and its highly flammable nature necessitating flame retardant additives for specific applications.

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Nylon – Nylon resin is a plastic derived from long-chain synthetic polymer molecules. It finds extensive use across diverse products and applications, including clothing, electronics, automotive components, and industrial machinery. Renowned for its strength, durability, and flexibility, nylon resin emerges as an ideal material for numerous applications.

Nevertheless, nylon does exhibit certain drawbacks, such as poor weather resistance, limited chemical resistance, high shrinkage, challenges in machinability, and a relatively higher cost.

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PETG – PETG resin is a thermoplastic polymer derived from glycol and terephthalic acid, commonly utilized in the production of film, fiber, food packaging, and various consumer products. Recognized for its exceptional durability and resistance to heat and chemicals, PETG resin is also esteemed for its flexibility and transparency, rendering it an excellent choice for 3D printing.

Nevertheless, PETG does have its drawbacks. It is susceptible to hydrolysis and can pose challenges during the printing process. Maintaining a consistent layer height requires a heated bed and a cooling fan, and PETG resin typically commands a higher price compared to other filament types.

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PLA – PLA resin is a bioplastic crafted from renewable sources like corn starch, sugarcane, and tapioca roots. It is biodegradable, non-toxic, and commonly employed in the fabrication of 3D-printed parts and components. Praised for its user-friendly nature, affordability, and robust mechanical properties, PLA is a popular choice in the realm of 3D printing.

However, PLA resin does come with its limitations. It is unsuitable for high-temperature environments and lacks food safety certification. Moreover, PLA is not UV resistant, poses challenges during handling compared to other materials, and demands additional time and effort to achieve quality prints. Additionally, it falls short in terms of strength and durability when compared to materials like ABS or PETG.

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Polycarbonate – Polycarbonate resin is a thermoplastic material synthesized from the monomers bisphenol A and phosgene. Renowned for its exceptional strength, heat resistance, and lightweight nature, polycarbonate finds application in a myriad of industries, including automotive, medical, aerospace, and security. It is also employed in the production of engineering plastics, injection molded parts, and thin films.

Despite its numerous advantages, polycarbonate resin does exhibit certain drawbacks. It is prone to UV degradation, susceptible to attack from solvents and acids, and vulnerable to stress cracking induced by mechanical stress or thermal shock. Additionally, polycarbonate resin tends to be more costly compared to other plastic resins.

For prototyping and general-purpose projects, PLA and ABS plastics remain popular choices. However, for specialized applications such as medical models or intricate miniatures, resins like nylon or polycarbonate may be more suitable. Resin materials such as epoxy, polyurethane, and silicone can also be leveraged for projects necessitating high strength and flexibility.

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