Materials guide
Industrial 3D printing materials.
The properties, thermal environment requirements and typical applications of the thermoplastics used in industrial 3D printing, from standard filaments to high-performance polymers, with four questions for choosing the right material.
Four questions for material selection
- Operating temperature: At what temperature will the part carry load? The material's thermal resistance must be safely above the operating temperature.
- Mechanical load: Which is decisive: impact, sustained load, fatigue or stiffness?
- Environment: Will the part be exposed to chemicals, UV radiation, moisture, hot steam or sterilisation?
- Regulations: Requirements such as flame-smoke, food contact or medical use are met by the appropriate material grade and its documentation.
Material comparison table
| Material | Strengths | Points to watch | Typical use |
|---|---|---|---|
| PLA | Easy to process, low warping, good dimensional stability | Low heat resistance (glass transition about 60 °C) | Concept models, casting patterns, mock-ups |
| ABS | Toughness, machinability, surface suited to finishing | Tends to warp; needs an enclosed chamber | Functional prototypes, housings, fixtures |
| ASA | Mechanical behaviour similar to ABS, UV and weather resistance | Needs an enclosed chamber | Outdoor parts, exterior vehicle and boat parts |
| PA / Nylon | Toughness, wear and fatigue resistance | Absorbs moisture; drying is essential | Gears, hinges, fixtures, wear parts |
| PC | High impact strength, good heat resistance | High print temperature, tends to warp | Fixtures, housings, thermoforming moulds |
| Fibre-filled (PA-CF, PEEK-CF) | High stiffness, low weight, dimensional stability | Abrasive; needs a wear-resistant nozzle, strength depends on direction | Stiff fixtures, brackets, robot grippers |
| PPS | Chemical resistance, inherent flame retardancy | Can behave brittle; needs a high-temperature environment | Components in chemical environments, electrical |
| PPSU | Impact, hydrolysis and sterilisation resistance | High processing temperature | Medical instruments, fluid components |
| PEI / ULTEM | High heat resistance, flame-smoke-toxicity performance | High nozzle and chamber temperature | Aircraft interiors, tooling, electrical |
| PEKK | High strength, wider process window than PEEK | High processing temperature | Aerospace and defence parts |
| PEEK | High-temperature and chemical resistance, metal replacement | Narrow process window; needs a heated chamber | Energy, medical, aerospace, defence |
The table shows general tendencies; properties vary by material grade and manufacturer. Design should be based on the data sheet of the material actually used.
Standard materials: PLA, ABS, ASA
With its low tendency to warp and good dimensional stability, PLA suits concept models, casting patterns and large mock-ups; its low heat resistance, however, rules it out for parts carrying load in warm environments. ABS is tougher and more machinable; ASA offers similar behaviour plus resistance to UV and weather, which makes it the choice for outdoor parts. ABS and ASA require an enclosed, heated chamber to prevent warping.
Engineering materials: PA and PC
PA (nylon) stands out for gears, hinges and fixtures thanks to its toughness and its wear and fatigue resistance; because it absorbs moisture, it must be dried before printing and fed from a dry environment. PC offers high impact strength and good heat resistance; its high print temperature and tendency to warp call for a controlled chamber.
Fibre-filled materials
Carbon or glass fibre increases the stiffness and dimensional stability of the polymer, so stiffer fixtures, brackets and grippers can be produced without adding weight. Because the fibres are abrasive, a standard brass nozzle wears quickly; a wear-resistant nozzle is required. As the fibres align with the print direction, mechanical behaviour becomes more dependent on layer orientation.
High-performance polymers
PPS, PPSU, PEI (ULTEM), PEKK and PEEK are used for demanding conditions such as high temperature, chemical environments, flame-smoke requirements or sterilisation. These materials require high nozzle temperatures, a heated chamber and careful material preparation. For details, see the PEEK 3D printing guide.
Thermal environment: what each material needs
- Heated bed: Often sufficient for low-warp materials such as PLA.
- Enclosed, heated chamber: Prevents warping and layer separation with materials such as ABS, ASA, PC and PA.
- High-temperature environment: PEI, PPSU, PEKK and PEEK require high chamber temperatures together with high nozzle temperatures.
Moisture and material storage
Materials such as PA, PC, PEI, PPSU and PEEK absorb moisture from the air. Moist filament causes bubbles, surface defects and loss of strength. Materials should be dried under the conditions recommended by the manufacturer, stored in a closed, dry environment and fed dry during long job cycles.
Materials processed on the BPT 2010
- Standard
- PLA, ABS, ASA, PA / Nylon, PC
- High performance
- PEEK, PEKK, PPS, PPSU, ULTEM / PEI
- Fibre-filled
- Carbon / glass fibre-filled materials (e.g. PA-CF, PEEK-CF), with a wear-resistant nozzle
- Thermal environment
- Nozzle 450 °C · chamber 170 °C · bed up to 180 °C
- Dual material
- Model and support material in the same print with the independent dual extruder
Frequently asked questions about 3D printing materials
Which material should be chosen for industrial 3D printing?
The choice follows the part's operating temperature, mechanical load, environment and relevant regulations. PLA is common for models and casting patterns, ABS, PA or PC for functional parts and fixtures, and PEI, PEKK or PEEK for high temperatures and chemical environments.
Which material is best for jigs and fixtures?
PA stands out for toughness and wear resistance, PC for impact strength, and fibre-filled materials such as PA-CF for high stiffness. Fixtures exposed to heat require polymers with higher temperature resistance.
Which material suits parts used outdoors?
ASA is a common choice thanks to its resistance to UV radiation and weather.
Why do fibre-filled materials need a special nozzle?
Carbon and glass fibres are abrasive and quickly wear standard nozzles. On the BPT 2010, fibre-filled materials are printed with a wear-resistant nozzle.
Which material should be chosen for parts operating at high temperature?
Depending on the operating temperature and environment, PC, PEI (ULTEM), PPSU, PEKK or PEEK are considered. PEEK stands out where the highest temperature and chemical resistance are required.
Let's choose the right material for your part.
Share the operating conditions and requirements of your part; our technical team will assess material suitability and, if you wish, print a sample.