Fused Deposition Modeling (FDM) – Materials

Fused Deposition Modeling (FDM) – Materials

Fused Deposition Modelling (FDM) printers are one of the most common types of 3D printers, and they work by extruding thermoplastic filaments layer by layer to create a physical object as shown below in Figure1. There are various materials (filaments) used in FDM printing, each with its own properties, strengths, and applications. Here's a detailed breakdown of the most common filaments:

  1. PLA (Polylactic Acid)
  2. ABS (Acrylonitrile Butadiene Styrene)
  3. PETG (Polyethylene Terephthalate Glycol-Modified)
  4. TPU (Thermoplastic Polyurethane)
  5. Nylon
  6. PC (Polycarbonate)
  7. HIPS (High Impact Polystyrene)
  8. PVA (Polyvinyl Alcohol)
  9. Carbon Fiber Reinforced Filaments
  10. Wood Fill Filaments
  11. Metal Fill Filaments
  12. Conductive Filaments

Figure 1: Illustration of Fused Deposition Modeling Printer.

PLA (Polylactic Acid)

Material Information:

  • Derived from renewable resources like cornstarch or sugarcane.
  • Biodegradable under industrial composting conditions.
  • Low printing temperature (180-220°C).
  • Minimal warping, making it ideal for beginners.

Chemical Composition:

  • Polymer Type: Biopolymer derived from renewable resources (cornstarch, sugarcane).
  • Chemical Formula: (C3-H4-O2)n
  • Molecular Structure: Linear aliphatic polyester.

Chemical Properties:

  • Biodegradable: Decomposes in industrial composting conditions.
  • Resistant to Acids & Bases: Fairly stable but degrades in alkaline environments.
  • Hydrophobic: Absorbs minimal moisture but can degrade in prolonged humid conditions.
  • Non-Toxic: Safe for food-related applications (if food-safe certified).

Chemical Resistance:

  • Weak against strong acids, bases, and solvents.
  • Decomposes in extreme heat (>60°C).

Applications:

  1. Prototyping: PLA is widely used for creating quick, non-functional prototypes.
  2. Decorative Items: Used for figurines, vases, and other artistic projects.
  3. Educational Models: Schools and universities use PLA for 3D printed learning tools.
  4. Medical Applications: Biocompatible forms of PLA are used for medical implants that dissolve over time.
  5. Printing on Demand: Used for prints that are daily used tools, objects, presentation for a cheap price.

ABS (Acrylonitrile Butadiene Styrene)

Material Information:

  • A petroleum-based thermoplastic that is tougher than PLA.
  • High impact and heat resistance (printing temperature: 210-250°C).
  • Produces fumes when printing, requiring good ventilation.
  • Requires a heated bed to prevent warping.

Chemical Composition:

  • Polymer Type: Thermoplastic copolymer.
  • Chemical Formula: (C8-H8·C4-H6·C3-H3-N)n
  • Structure: Composed of three monomers:
    • Acrylonitrile: Provides chemical resistance.
    • Butadiene: Adds toughness and flexibility.
    • Styrene: Improves printability and surface finish.

Chemical Properties:

  • Soluble in Acetone: Can be chemically smoothed using acetone vapor.
  • Heat Resistant: Can withstand up to 100°C before softening.
  • Hydrophobic: Does not absorb water easily.
  • Releases Fumes: Emits styrene gas when heated, requiring proper ventilation.

Chemical Resistance:

  • Resistant to oils, fats, and most acids.
  • Weak against strong solvents like acetone and MEK.

Applications:

  1. Consumer Products: Used in toys like LEGO bricks and household items.
  2. Automotive Parts: Due to its durability and heat resistance, ABS is used in dashboards, trims, and housings.
  3. Enclosures & Casings: Ideal for electronic housings such as remotes and game controllers.
  4. Functional Prototypes: Useful for mechanical components that require toughness.

PETG (Polyethylene Terephthalate Glycol-Modified)

Material Information:

  • Stronger than PLA and more flexible than ABS.
  • Resistant to impact, water, and chemicals (Printing temp: 220-250°C).
  • Minimal warping and stringing issues.
  • Food-safe variants exist.

Chemical Composition:

  • Polymer Type: Thermoplastic polyester.
  • Chemical Formula: (C10-H8-O4)n
  • Structure: Similar to PET (used in water bottles) but glycol-modified (G) to improve flexibility.

Chemical Properties:

  • High Chemical Resistance: Resists water, acids, alcohols, and oils.
  • Hydrophobic: Does not absorb much moisture.
  • Food Safe: Some PETG variants are FDA-approved.
  • Heat Resistant: Can withstand up to 80°C.

Chemical Resistance:

  • Strong resistance to chemicals, but susceptible to some hydrocarbons (benzene, toluene).

Applications:

  1. Food Containers & Bottles: Some PETG formulations are food-safe, making them useful for cups and storage containers.
  2. Mechanical Components: Gears, hinges, and other semi-flexible parts.
  3. Medical Devices: Used for protective face shields, prosthetics, and biomedical applications.
  4. Weather-Resistant Items: Suitable for outdoor use as it does not degrade as fast as PLA.
  5. Toughness & Flexibility: Used for tools that requires both flexibility and toughness in which it resists brittleness.

TPU (Thermoplastic Polyurethane)

Material Information:

  • Highly flexible and elastic material with excellent impact resistance.
  • Prints at 210-240°C with slow print speeds.
  • Resistant to abrasion, grease, and some chemicals.

Chemical Composition:

  • Polymer Type: Thermoplastic elastomer.
  • Chemical Formula: Varies (based on urethane groups and polymer backbones).
  • Structure: Composed of soft (polyether/polyester) and hard (isocyanate) segments.

Chemical Properties:

  • Highly Flexible & Elastic: Can stretch significantly without breaking.
  • Resistant to Oils & Grease: TPU is used in automotive seals.
  • Hydrophilic: Can absorb moisture, requiring dry storage.
  • Heat Tolerant: Withstands temperatures up to ~80°C.

Chemical Resistance:

  • Excellent resistance to oils, grease, and solvents.
  • Weaker against strong acids and UV exposure.

Applications:

  1. Wearables & Fashion: Shoe insoles, watch straps, and flexible clothing accessories.
  2. Medical Use: Prosthetic components and orthopedic devices.
  3. Automotive: Used in seals, gaskets, and vibration-dampening parts.
  4. Phone Cases & Protective Covers: TPU provides impact resistance for protective cases.

Nylon

Material Information:

  • Tough, semi-flexible, and impact-resistant.
  • High heat resistance (printing temperature: 240-270°C).
  • Hygroscopic (absorbs moisture easily), requiring proper storage.

Chemical Composition:

  • Polymer Type: Synthetic polyamide.
  • Chemical Formula: (C12-H22-N2-O2)n (for Nylon-6,12)
  • Structure: Long polymer chains with strong intermolecular hydrogen bonding.

Chemical Properties:

  • Hygroscopic: Absorbs moisture, requiring sealed storage.
  • Self-Lubricating: Low friction, making it ideal for moving parts.
  • High Heat Resistance: Can withstand temperatures above 120°C.

Chemical Resistance:

  • Resistant to alcohols, ketones, and some hydrocarbons.
  • Weak against strong acids and bases.

Applications:

  1. Gears & Bearings: Commonly used in high-stress mechanical applications.
  2. Functional Prototypes: Strong enough for testing moving parts.
  3. Industrial Use: High-strength, low-friction applications like bushings and rollers.
  4. Sports Equipment: Used in protective gear and sports-related applications.

PC (Polycarbonate)

Material Information:

  • One of the strongest 3D printing filaments.
  • High-temperature resistance (printing temp: 250-300°C).
  • Requires an enclosed chamber to prevent warping.
  • Transparent and available in clear variants.

Chemical Composition:

  • Polymer Type: Thermoplastic.
  • Chemical Formula: (C16-H14-O3)n
  • Structure: Composed of Bisphenol A (BPA) units.

Chemical Properties:

  • Extreme Heat Resistance: Withstands up to 150°C.
  • Impact Resistant: Used in bulletproof glass.
  • Hydrophobic: Does not absorb much moisture.
  • UV Resistant: Does not degrade easily under sunlight.

Chemical Resistance:

  • Resistant to weak acids, alcohols, and oils.
  • Weak against strong bases and some organic solvents (acetone).

Applications:

  1. Protective Equipment: Bulletproof glass, safety goggles, and riot shields.
  2. Automotive: High-performance components exposed to heat.
  3. Aerospace: Used in lightweight yet durable parts.
  4. Electronics: PC is used in electrical enclosures and heat-resistant cases.

HIPS (High Impact Polystyrene)

Material Information:

  • Similar to ABS but dissolves in limonene.
  • Often used as a support material in dual extrusion printers.
  • Prints at 230-240°C.

Chemical Composition:

  • Polymer Type: Polystyrene-based copolymer.
  • Chemical Formula: (C8-H8)n
  • Structure: Similar to ABS but dissolves in limonene.

Chemical Properties:

  • Dissolves in Limonene: Used as support material.
  • Lightweight: Lower density than ABS.
  • Moderate Heat Resistance: Up to ~100°C.

Chemical Resistance:

  • Resistant to water and mild chemicals.
  • Weak against strong acids and solvents.

Applications:

  1. Support Structures: Provides dissolvable support for complex overhangs.
  2. Prototyping: Used as a cheap alternative for test prints.
  3. Model Making: Used in architecture and industrial models.

PVA (Polyvinyl Alcohol)

Material Information:

  • Completely water-soluble support material.
  • Prints at 190-220°C.
  • Highly hygroscopic (absorbs water easily).

Chemical Composition:

  • Polymer Type: Water-soluble polymer.
  • Chemical Formula: (C2-H4-O)n
  • Structure: Composed of hydroxyl (-OH) groups that allow it to dissolve in water.

Chemical Properties:

  • Completely Water-Soluble: Dissolves in cold water.
  • Biodegradable: Safe for the environment.
  • Weak Heat Resistance: Starts degrading at ~60°C.

Chemical Resistance:

  • Not resistant to water.
  • Weak against strong acids and bases.

Applications:

  1. Support Structures: Used in complex multi-material prints.
  2. Medical & Pharmaceutical: Biodegradable capsules.
  3. Eco-Friendly Packaging: Used in dissolvable films.
  4. Disposable Materials: Used for tools, objects, or materials that are used once or twice. 

Carbon Fiber Reinforced Filaments

Material Information:

  • Composite material made of carbon fibers mixed with PLA, PETG, or Nylon.
  • Increases strength and stiffness while reducing weight.
  • Requires a hardened steel nozzle due to abrasiveness.

Chemical Composition:

  • Base Polymer: PLA, PETG, or Nylon mixed with carbon fiber particles.

Chemical Properties:

  • High Strength & Stiffness: Carbon fibers provide structural reinforcement.
  • Low Thermal Expansion: Less warping compared to pure plastics.
  • Heat Resistant: Up to 100-150°C, depending on the base polymer.

Chemical Resistance:

  • Dependent on the base polymer.
  • More brittle than unreinforced polymers.

Applications:

  1. Drones & Robotics: Lightweight yet strong parts.
  2. Automotive & Aerospace: Used for structural components.
  3. Sports Equipment: Racket frames, bicycle parts, and more.

Wood Fill Filaments

Material Information:

  • A mix of PLA and wood fibers to give a real wood appearance.
  • Prints at 180-220°C.
  • Can be sanded, stained, or painted.

Chemical Composition:

  • Base Polymer: PLA or ABS mixed with metal powders (copper, bronze, steel).

Chemical Properties:

  • Heavyweight: Feels like real wood.
  • Moderate Heat Resistance: ~80-100°C.

Chemical Resistance:

  • Similar to the base polymer but with higher thermal conductivity.

Applications:

  1. Decorative Items: Picture frames, ornaments, and sculptures.
  2. Furniture Prototyping: Used in design mockups for furniture.
  3. Architectural Models: Offers a wooden finish for detailed scale models.

Metal Fill Filaments

Material Information:

  • Contains metal powder mixed with PLA or ABS (Bronze, Copper, Steel, Aluminum).
  • Produces heavy, metallic-feel prints.
  • Can be polished or oxidized for antique effects.

Chemical Composition:

  • Base Polymer: PLA or ABS mixed with metal powders (copper, bronze, steel).

Chemical Properties:

  • Heavyweight: Feels like real metal.
  • Polishable & Oxidizable: Can be aged to create patina.
  • Moderate Heat Resistance: ~80-100°C.

Chemical Resistance:

  • Similar to the base polymer but with higher thermal conductivity.

Applications:

  • Jewelry & Art: Imitates real metal jewelry without casting.
  • Historical Replicas: Produces aged metal-look objects.
  • Decorative Items: Custom medals, trophies, and sculptures.
 Material  Strength Flexibility Heat Resistance Ease of Printing Applications
PLA Medium Low Low (~60°C) Very Easy Prototypes, toys, decorative items
ABS  High Medium Medium (~100°C) Moderate Functional parts, enclosures
PETG High Medium Medium (~80°C) Easy Food containers, mechanical parts
TPU  Low High Low (~60°C) Hard Phone cases, gaskets, wearables
Nylon Very High High High (~120°C) Hard Gears, industrial parts
PC Very High Medium Very High (~150°C) Hard Aerospace, automotive, protective gear
Carbon Fiber Very High Low High (~120°C) Hard Aerospace, drones, high-strength parts
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