Guide to 3D Printing Plastics Types Properties and Uses

In the rapidly evolving landscape of technological innovation, 3D printing has emerged as a transformative force reshaping traditional manufacturing paradigms. Among the diverse materials employed in additive manufacturing, plastics stand out as the most widely used and promising option. This article explores the fascinating world of 3D printing plastics, examining their varieties, characteristics, and applications.

Since the commercialization of the first 3D printing systems in the 1980s, plastic polymers have remained central to additive manufacturing technologies. Today, plastics continue to dominate as the most versatile and commonly used materials across all major 3D printing processes, including sheet lamination, material extrusion (FDM/FFF), material jetting, binder jetting, vat photopolymerization, and powder bed fusion.

The form and application of plastic materials vary significantly depending on the specific printing technology. Material extrusion typically employs plastic filaments for prototyping, while powder bed fusion techniques like HP's Multi Jet Fusion utilize plastic powders to achieve superior predictability, precision, strength, and part quality. Regardless of form, these materials undergo melting or fusion processes to construct objects layer by layer, with each plastic requiring unique parameters and yielding distinct mechanical properties.

HP has developed an expanding portfolio of thermoplastic materials specifically engineered for its Multi Jet Fusion technology, designed to push the boundaries of functional part manufacturing while optimizing cost efficiency and quality.

The current HP 3D printing materials lineup includes:

• PA 11
• PA 12
• PA 12 GB
• HP 3D High Reusability Polypropylene (PP)
• HP 3D High Reusability TPA

The High Reusability PP, developed with BASF, offers consistent performance with up to 100% powder reuse capability. The High Reusability TPA, created in collaboration with Evonik, is an elastomer material producing lightweight, flexible parts with enhanced rebound characteristics and exceptional uniformity.

ABS remains a staple thermoplastic in additive manufacturing, available in both filament form for FDM printing and powder form for SLS processes. Its popularity stems from widespread use in conventional manufacturing and its compatibility with additive techniques.

Key Properties:

• High strength and impact resistance
• Good thermal stability
• Excellent surface finish
• Chemical resistance
• Versatile processing options

Applications: Automotive components, electronic housings, toys, and consumer goods.

PLA distinguishes itself through biodegradability, derived from renewable resources like corn starch. Its ease of use makes it ideal for desktop 3D printing, though it exhibits slight shrinkage tendencies.

Key Properties:

• Eco-friendly composition
• Low printing temperatures (190-230°C)
• Good surface finish
• Moderate strength

Applications: Food packaging, biodegradable medical devices, prototypes, and agricultural products.

ASA shares many characteristics with ABS but offers superior UV resistance along with excellent thermal stability and impact strength.

Key Properties:

• Exceptional weather resistance
• High strength and durability
• Good thermal performance

Applications: Outdoor products, architectural elements, and signage.

Available in powder and filament forms, nylon's semi-crystalline structure delivers an optimal balance of chemical and mechanical properties.

Key Properties:

• Exceptional strength and wear resistance
• Chemical resistance
• Flexibility and toughness

Applications: Industrial components, textiles, automotive parts, and electronic connectors.

PETG, a modified version of PET, has gained popularity in 3D printing for its clarity and ease of use compared to standard PET.

Key Properties:

• High strength and toughness
• Excellent transparency
• Chemical resistance

Applications: Food packaging, medical devices, prototypes, and display items.

PC stands out as an engineering-grade material with exceptional strength and thermal resistance.

Key Properties:

• Extreme impact resistance
• High transparency
• Thermal stability (up to 150°C)

Applications: Electronic enclosures, automotive components, aerospace parts, and safety equipment.

Materials like PEEK, PEKK, and ULTEM offer metal-like mechanical properties with significantly reduced weight.

Key Properties:

• Exceptional strength and stiffness
• Superior thermal and chemical resistance
• Lightweight composition

Applications: Aerospace components, automotive engine parts, medical implants, and high-performance electronics.

Primarily used as soluble support material in FDM printing, HIPS dissolves completely in limonene hydrocarbon solution.

Key Properties:

• Good impact resistance
• Easy processing
• Solubility in limonene

Applications: Support structures for complex 3D prints, packaging, and displays.

Widely used in automotive and consumer goods manufacturing, PP offers excellent wear resistance and impact absorption.

Key Properties:

• Chemical resistance
• Thermal stability
• Good strength-to-weight ratio

Applications: Automotive components, medical devices, packaging, and household items.

These materials combine plastic matrices with reinforcing fibers to create lightweight yet exceptionally strong components.

Key Properties:

• High strength-to-weight ratio
• Excellent stiffness
• Corrosion resistance

Applications: Aerospace structures, automotive body panels, sports equipment, and medical prosthetics.

Soluble support materials like HIPS and PVA (Polyvinyl Alcohol) play crucial roles in complex 3D printing projects. PVA dissolves in water and works particularly well with PLA, while BVOH (Butenediol Vinyl Alcohol Copolymer) has emerged as an increasingly popular alternative with higher solubility rates than PVA.

The diverse landscape of 3D printing plastics continues to expand, offering manufacturers and designers an ever-growing toolkit for transforming digital concepts into physical reality. Material selection requires careful consideration of printing technology, performance requirements, and cost factors, with new innovations continually emerging to address evolving industry needs.