3d Printing
There is no doubt that 3D printing is amazing technology. However, the complex shapes you can make with 3D printing, while impressive and convenient, can lead inexperienced engineers and designers to gain a false sense of security in the success of their designs.
It's important to always bear in mind when using 3D printing during the prototyping process that you are eventually going to have to manufacture the components you are designing with alternate more conventional manufacturing processes. We've witnessed many designers take their 3D printed designs far along in the process to the point that they want to start to manufacture, only to have to completely redesign their products because the components can't be manufactured in volume, resulting in significant consequences. It's vital to design for the process you are going to use for prototype and keep in mind how it will need to be eventually manufactured.
As well, the strength, stiffness, and tolerances of 3D printed materials can be much different compared to production materials, risking the possibility of leading you astray if you don't plan for this in advance.
It is very common to be working on two different products designs in parallel later in the product development cycle. One version of the product design is used for prototype testing and design validation. The other design is then intended for mass production. This concurrent engineering approach, while resource intensive, yields the lowest risk approach and the fastest time to market.
FILAMENTS
3D printing filament is created using a process of heating, extruding and cooling plastic to transform nurdles into the finished product. Unlike a 3D printer the filament is pulled rather than pushed through the nozzle to create the filament, the diameter of the filament is defined by the process that takes place after the plastic has been heated rather than the diameter of the extruder nozzle. A different force and speed is applied to the filament as it is pulled out of the extruder to define the width of the filament, most commonly 1.75 mm or 3 mm diameter.
PLA Polylactic Acid
EXTRUDER TEMP
205±15 °C
BED TEMP
40±15 °C
BED ADHESION
Blue Painters Tape
PLA (Polylactic Acid) is one of the two most commonly used desktop 3D printing filaments (with the other being ABS filament). It is the "default" recommended material for many desktop 3D printers, and with good reason - PLA is useful in a broad range of printing applications, has the virtue of being both odorless and low-warp, and does not require a heated bed. PLA filament is also one of the more eco-friendly 3D printer materials available; it is made from annually renewable resources (corn-starch) and requires less energy to process compared to traditional (petroleum-based) plastics. Outside of 3D printing, PLA plastic is often used in food containers, such as candy wrappers, and biodegradable medical implants, such as sutures. PLA filament for 3D Printing is available in a wide range of colors
PLA 3D Printing Filament Properties:
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PLA filament is a stiff but brittle 3D printing material.
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Best used for cosmetic prints, prototypes, desk toys, low-stress applications.
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Best 3D printer material for beginners due to ease of printing and minimal warp.
ABS Acrylonitrile Butadiene Styrene
EXTRUDER TEMP
230±10 °C
BED TEMP
90±10 °C
BED ADHESION
Kapton Tape / Hairspray
ABS (Acrylonitrile Butadiene Styrene) is another commonly used 3D printer material. Best used for making durable parts that need to withstand higher temperatures. In comparison to PLA filament, ABS plastic is less "brittle" and more "ductile." It can also be post-processed with acetone to provide a glossy finish. When 3D printing with ABS filament, a heated printing surface is recommended, as ABS plastic will contract when cooled leading to warped parts.
ABS 3D Printing Filament Properties:
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ABS filament is strong, ductile material with wear resistance and heat tolerance.
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Common 3D prints with ABS are Interlocking parts like gears, parts exposed to UV and heat like a car cup holder, or prototyping.
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Wide selection of methods for excellent post-processing.
Nylon Polyamide
EXTRUDER TEMP
255±15 °C
BED TEMP
70±10 °C
BED ADHESION
PVA-Based Glue
Nylon is an incredibly strong, durable, and versatile 3D printing material. Flexible when thin, but with very high inter-layer adhesion, nylon lends itself well to things like living hinges and other functional parts. Nylon filament prints as a bright natural white with a translucent surface, and can absorb color added post process with most common, acid-based clothing dyes or synthetic cloth specific dyes. Nylon filament is extremely sensitive to moisture, so taking drying measures during storage and immediately prior to printing (using desiccant, vacuum, or elevated temperature) is highly recommended for best results.
Nylon 3D Printing Filament Properties:
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Nylon filament is strong yet flexible making it tough to break and shatter resistant.
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Commonly used for living hinges, functionally strong parts.
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Must be dried before printing for strength and a glossy finish.
PET (PETG, PETT) Polyethylene Terephthalate
EXTRUDER TEMP
245±10 °C
BED TEMP
60±10 °C
BED ADHESION
Blue Painters Tape
You'll be hard pressed to find true PET (Polyethylene terephthalate) filament, as most PET filaments are actually copolymers - PET with an extra molecule. The most common, PETG filament, is an industrial strength filament with several great features. Figuratively speaking, it combines the ease of use of PLA filament with the strength and durability of ABS filament. First, its strength is much higher than PLA and it is FDA approved for food containers and tools used for food consumption. Unlike ABS filament, it barely warps, and produces no odors or fumes when printed. PET filament is not biodegradable, but it is 100% reclaimable. It's known for its clarity and is also very good at bridging.
PLA 3D Printing Filament Properties:
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PET filament is a durable and flexible 3d printing material with a glossy finish and is impact and heat resistant.
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Best used for mechanical parts and snap fit enclosures.
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Sticks incredibly well to blue painters tape.
PolyPropylene PP
EXTRUDER TEMP
250±15 °C
BED TEMP
110±10 °C
BED ADHESION
Packing Tape
PolyPropylene filament (PP) has a number of uses as a 3D printing material. Its best use is for packaging, food-safe containers, and living hinges. Polypropylene materialm has a much better ability to elongate without breaking when compared to PLA filament. It also resists impact better than PLA as well. Where PLA plastic tends to shatters and snap while Polypropylene plastic bends and squeezes into place. However, Polypropylene can be difficult to stick well to most print surfaces, including glass, kapton tape, PEI, and some packaging tapes. Most packaging tape is made with Polypropylene and it will stick to that, otherwise it won't work. With the right type of packaging tape, a bed temperature of 120°C and an extrusion temperature of 240°C produces great prints.
PolyPropylene 3D Printing Filament Properties:
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PolyProylene filament is flexible and chemically inert 3D printing material.
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Commonly used for living hinges, medical devices, and chemistry equipment.
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Very hygroscopic, making drying before printing an essential step.
ASA Acrylonitrile Styrene Acrylate
EXTRUDER TEMP
250±10 °C
BED TEMP
90±10 °C
BED ADHESION
Hairspray
Acrylonitrile styrene acrylate (ASA) was developed as an alternative to ABS. With a number of additional features, like improved weather resistance and resistance to yellowing from UVs, making it an excellent choice for parts or prints meant for outdoor use. Where white ABS will turn a pale yellow over time, ASA will remain a bright white for much longer. ASA has print settings very similar to ABS with only the printing temperature being different. ASA filament is available in several colors in both 1.75mm and 3mm.
ASA 3D Printing Filament Properties:
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ASA filament is a UV, weather, and temperature resistant material in addition to regular ABS properties.
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Best used for outdoor clips, planters, fixtures, other outdoor parts.
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If you're printing something designed for outdoor use, ASA should be your go to 3D printing material.
TPU Thermoplastic Polyurethane
EXTRUDER TEMP
250±10 °C
BED TEMP
50±10 °C
BED ADHESION
Blue Painters Tape
TPU (Thermoplastic Polyurethane) is an elastic, oil/grease resistant, and abrasion-resistant material with a shore hardness of 95A. TPU Plastic has several applicable uses including automotive instrument panels, caster wheels, power tools, sporting goods, medical devices, drive belts, footwear, inflatable rafts, and a variety of extruded film, sheet and profile applications. It is also commonly used in mobile phone cases.
TPU 3D Printing Filament Properties:
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TPU filament creates rubbery, elastic, and impact resistant parts.
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Best used for stoppers, belts, caps, phone cases, bumpers and more.
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The less infill you use, the more flexible your finished print will be.
Polycarbonate Pc
EXTRUDER TEMP
290±20 °C
BED TEMP
130±15 °C
BED ADHESION
Glue Stick / Hairspray
Polycarbonate (PC) Polycarbonate is strong and very resistant to impact - this material is used when making bullet-proof glass. Not only is polycarbonate an extremely tough and durable thermoplastic material it is also very restistant to temperature. This material is malleable when cool and can bend without cracking.
PC 3D Printing Filament Properties:
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PC filament extremely high temperature resistant and impact resistany.
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Potential uses in printed RC parts or drone parts.
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An all-metal hotend for this high-temp material is required.
TPE
EXTRUDER TEMP
220±10 °C
BED TEMP
30±10 °C
BED ADHESION
Blue Painters Tape
TPE filament is a flexible 3D printing material that feels and acts much like flexible rubber. TPE filament can be used to make parts that can bend or must flex to fit their environment: stoppers, belts, springs, phone cases, and more. This extremely flexible 3D printer material will allow you to create 3D prints that will have the properties of a soft rubber, making it even more flexible and elastic than our Soft PLA filament. Due to its flexibility, much slower print speeds must be used to keep the filament from binding in the extruder.
TPE 3D Printing Filament Properties:
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TPE filament creates rubbery, elastic, and impact resistant parts.
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Best used for stoppers, belts, caps, phone cases, bumpers and more.
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The less infill you use, the more flexible your finished print will be.
Bendlay
EXTRUDER TEMP
225±15 °C
BED TEMP
35±10 °C
BED ADHESION
Blue Painters Tape
Bendlay is an exciting new filament that is extremely translucent (91% of light passes through) and also is quite flexible. This extremely translucent material will allow you to print nearly clear items, while at the same time being remarkably resilient and elastic. BendLay is a modified Butadiene, which is safe for household and food products. BendLay has a high interlayer adhesion, making it a really easy-to-print filament. Compared to ABS filament, it absorbs far less moisture from the air and thus cuts down on warping significantly.
BendLay 3D Printing Filament Properties:
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BendLay filament is a tough and ductile 3D printing material with 91% light transmission.
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Best used ornate cups, containers, or translucent objects.
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High layer adhesion and food-safe means you can print ornate cups and containers with this filament.
PVA Polyvinyl Alcohol
EXTRUDER TEMP
180±20 °C
BED TEMP
45±10 °C
BED ADHESION
Blue Painters Tape
PVA (Polyvinyl Alcohol) filament prints translucent with a slightly yellow tint and is primarily used as a 3D printing support material because it is water-soluble, meaning that it will dissolve when exposed to water (and so MUST be kept dry prior to use). PVA is most often used with 3D printers capable of dual extrusion: one extruder printing a primary material (such as ABS or PLA) and the other printing this dissolvable filament to provide support for overhanging features.
PVA 3D Printing Filament Properties:
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PVA filament is a stiff, water soluble 3d printing support material.
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Best used for models with internal supports or supports for incredibly detailed models with many overhangs.
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Best 3D printer support material for PLA because of similar printing temperatures
HIPS High Impact Polystyrene
EXTRUDER TEMP
230±10 °C
BED TEMP
50±10 °C
BED ADHESION
Kapton Tape / Hairspray
High Impact Polystyrene (HIPS) is very similar to ABS. The main difference is that HIPS plastic can be dissolved using Limonene as a solvent, therefore making it a great option as support material when printing ABS with dual extrusion printer. HIPS filament is as easy to 3D print with as ABS but is much less likely to warp.
HIPS 3D Printing Support Filament Properties:
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HIPS filament is a rigid, support material that dissolves away in limonene.
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Best used for models with internal supports or supports for incredibly detailed models with many overhangs.
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Best 3D printer support material for ABS because of similar printing temperatures.
Carbon Fiber Reinforced PLA
EXTRUDER TEMP
210±10 °C
BED TEMP
50±10 °C
BED ADHESION
Blue Painters Tape
Carbon Fiber Reinforced PLA filament provides excellent structural strength and layer adhesion with very low warpage. Due to the carbon fiber contained in the filament, it has increased rigidity, therefore increased structural support is built right in. The carbon fiber in the filament is specifically designed to be small enough to fit through the nozzles, but long enough to provide the extra rigidity that makes this reinforced PLA necessary for any hobbyist that needs rugged prints. Carbon Fiber filament is perfect for printing items that should not bend, such as: frames, supports, propellers, and tools. Drone builders and RC Hobbyists love this filament. Due to its high abrasion, before printing you will need to install a hardened steel nozzle on your printer.
Carbon Fiber Reinforced PLA 3D Printing Filament Properties:
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Carbon Fiber Reinforced PLA filament is a strong, ductile material with wear resistance and heat tolerance
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Best used for drone bodies, propellers, and RC car frames.
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PLA provides ease of printing, carbon fiber provides rigidity.
Wood Filaments
EXTRUDER TEMP
220±30 °C
BED TEMP
30±10 °C
BED ADHESION
Blue Painters Tape
Wood-like 3D printer materials give 3D printed objects the look and feel of fiberboard. They imbue parts with other wood-like attributes, such as the ability be cut, painted, and sanded. These filaments use PLA as their base, and mix other materials (usually in powder form)into them. The PLA gives the 3D printer compatibility and ease of use while the material contributes to the look, feel, and properties of the filament. You get the color and texture of real wood with your finished prints, but with Corkfill, you get the added benefit of its light weight. With these organic fills, be cautious of too high of a temperature, as it will result in the wood burning which will give you a darker colored print. It is important to remove the filament from the extruder fairly soon after finishing a print, as the filament will begin to burn in the nozzle and start to clog it.
Wood PLA 3D Printing Filament Properties:
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Wood filaments looks and feels similar to actual wood with printing properties of PLA.
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Best used for wooden busts, sculptures, or tikis. Anything really complex to chisel.
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Different extruder temperatures produce different colors; the hotter, the darker.