3D Printer Material | from plastic to metal

The Filaments and materials for 3D printing are constantly evolving. The current state of development indicates an increasing variety and higher performance 3D printer Materials, which last but not least meet the often robust requirements in industry. In addition to sustainability, the components must also be increasingly high-performing. In this article you will find out what is available and where the journey is going.

 

Contents

• Development status of 3D printer materials
  • Specialized for the industry
• New 3D printing filaments and materials
  • SLS printing material with 110°C temperature resistance
  • 3D printing resin significantly increases service life
  • First elastomer for 3D printers of the Fuse series
  • Extremely strong 3D printing filament with fiber reinforcement
  • Thermoplastic polyimide for high temperature use
  • iglidur I190 beats POM and nylon
  • Aluminum alloy for aircraft components
  • Filaments according to EU regulation and FDA
  • Photopolymer for industrial 3D printing applications
  • High temperature polyamide Luvocom 3F PA for 3D printing
  • Filaments for 2-component 3D printing in one step
  • Liquid materials for industrial liquid additive manufacturing
• Archive for 3D printing materials news
• FAQ

 

Development status of 3D printer materials

to the am commonly used3D printer materials include ABS (acrylonitrile butadiene styrene), PLA (polylactic acid) and PETG (polyethylene terephthalate). ABS is a strong and impact resistant material, PLA is a biodegradable material and PETG is stronger and more resilient than PLA.

Compared to these traditional options new materials enter the market. An example is nylon, which offers high strength, flexibility, and impact resistance. Flexible filaments such as TPU (thermoplastic polyurethane) make it possible to create elastic parts, while wood and metal filaments give the printed object a natural look or metallic properties. There are also composite materials such as carbon fiber filaments, which have high rigidity and strength.

---

Solidworks 2023 | CAD software by and for users

---

A pair of future trend lies in the development of environmentally friendly options. Biodegradable filaments such as PLA and PHA (polyhydroxyalkanoates) are becoming more popular because they offer a more sustainable alternative to traditional plastics. Another promising trend is advanced materials that allow the printing of complex structures. For example, there are TPU filaments with a higher shore hardness that enable the printing of technical elastomers and industrial components.

Specialized for the industry

In industry, 3D printing is having a significant impact on manufacturing and the demand for specific filaments and materials. These often have to robust requirements increasingly fair to the industry.

Engineering plastics such as ABS, nylon and PC (polycarbonate) are in high demand here because their high strength, durability and heat resistance make them ideal for the production of functional Prototypes and end products are suitable. In addition, composite materials such as carbon fiber reinforced nylon are gaining in popularity because they offer even greater rigidity and strength.

An important trend in industrial 3D printing is the development of high performance materials. This includes filaments with improved properties such as increased temperature resistance, chemical resistance and improved mechanical properties. These materials enable 3D printing to be used for more demanding applications such as the manufacture of tools, molds and functional end products.

Another trend is the introduction of metal filaments for 3D printing. Metal 3D PrintingProcesses such as selective laser melting (SLM) or electron beam melting (EBM) enable the production of complex metallic components. These technologies require special metal powders that can be used in filaments. Metal filaments open up new possibilities in the additive manufacturing of metal components, both for prototypes and for small series production. When it comes to eco-friendly materials, companies are increasingly looking for more sustainable options to reduce the environmental impact of 3D printing. 

New 3D printing filaments and materials

Overall, it shows that the industry has a growing need for specialized and high-performance filaments and materials for 3D printing. Advances in materials development and increasing diversity are making it possible to use 3D printing in more and more applications, and slowly suitable for the masses close. Future trends are expected to include even greater material diversity and continued improvement in properties and performance. We present the new products on the market below: 

SLS printing material with 110°C temperature resistance

30.01.2024 | Igus brings the first 3D printing material for polymer components with a temperature resistance of up to 110°C onto the market. The new powdered material Iglidur i230 can withstand long-term use at high temperatures. In addition, the material is PTFE-free and approx. 80% more wear-resistant than the classic PA12.

To the post

---

3D printing resin significantly increases service life

21.07.2023 | Igus presents with iglidur i3000 the world's first 3D printing resin for DLP 3D printing of wearing parts. After curing, the construction platform is lowered by one layer so that the next exposure can take place. This is how layer by layer is created tiny components such as gears with tips that measure only 0,2 mm and which have a very smooth surface without any further treatment. 

To the post

First elastomer for 3D printers of the Fuse series

14.07.2023/90/XNUMX | With the new TPU XNUMXA Powder for the Fuse series Formlabs can be resilient, skin-friendly and affordable components for the Medical Technology, manufacturing, engineering and consumer goods industries in the manufacturer's SLS 3D printing Fuse series. The parts achieve a high tear resistance and elasticity.

Users can join TPU 90A independently produce functional parts in-house. You enjoy design freedom and a seamless workflow within the SLS 3D printing ecosystem. The material closes the gap between the individual production stages by providing fully functional prototypes, Tools and end-use parts can be manufactured. And the powder is suitable for making soft-touch components for gripping arms, padding and dampers. 

It is skin-friendly and is suitable for medical applications such as prostheses, orthotics and other patient-specific devices that require individual design. Parts made of soft, flexible 90A TPU offer a high level of comfort for optimal healthcare and a simplified manufacturing process for medical devices. “At Formlabs, we want to empower our customers to really make anything from medical components to wearables,” says David Lakatos, Chief Product Officer at Formlabs. “We are proud that TPU 90A Powder is expanding the possibilities for 3D printing across industries. With the material, users can produce flexible, skin-friendly parts that are tailored to their individual needs.”

Advantages of the TPU 90A Powder

• high tear strength and elongation at break 110 to 310%
• low cost per part for low volume production
• Skin compatibility for printing medical wearables and devices
• reduced waste and higher efficiency with 20% recycle rate.

Extremely strong 3D printing filament with fiber reinforcement

15.08.2022/3/XNUMX | The new igus XNUMXD printing filament Igumid P190 enables extremely stiff and solid 3D printing thanks to carbon fiber reinforcement. It is suitable for structural components and special connection elements energy chains as well as 2-component 3D printing in combination with iglidur i190. Igumid P190 is available as a filament for self-printing and in the future in the 3D printing online service.

To the post

---

Thermoplastic polyimide for high temperature use

01.09.2021 | The thermoplastic Polyimide Aurum is a highly heat-resistant super engineering plastic with high production efficiency in the injection molding sector. The thermal plastic challenges the conventional wisdom that polyimide is very powerful but difficult to process. Bieglo presents the PI portfolio, which is also suitable for 3D printing.

To the post

---

iglidur I190 beats POM and nylon

22.02.2021 | In a test The iglidur I3800 has proven its longevity in its own 190 m² laboratory. A 3D printed iglidur I190 bearings competed against additively manufactured bearings made of ABS and polyamide as well as turned and injected bearings made of POM and nylon. As a result, the printed Igus bearing was up to 50 times more abrasion resistant than standard plastic bearings.

To the post

---

Filaments according to EU regulation and FDA

07.09.2021 | When manufacturing the large-format parts from the 3D printer Igus in particular the tribofilaments Iglidur I150 and the optically detectable blue variant Iglidur I151. The plastics are according to the EU Regulation 10 / 2011 for the Food industry Iglidur I151 is also certified FDA compliant.

To the post

Photopolymer for industrial 3D printing applications

04.05.2021 | Evonik has developed two photopolymers for industrial 3D applications with the brand names Infinamt TI 3100 L and Infinam ST 6100 L. The two ready-to-use materials form the beginning of a new synthetic resin product line. Each polymer is suitable for use in common photopolymer 3D printing processes such as SLA or DLP. 

"With the new product line, we are entering the market-relevant photopolymer technology line and thus strengthening our long-term market position as material experts for all important polymer-based 3D printer technologies," says dr Dominic Stoerkle, Head of Additive Manufacturing at Evonik. "With the new ready-to-use formulations, we are also continuing our material offensive and promoting 3D printing as a large-scale industrial production along the entire value chain."

Photopolymer for mechanical effects 

The first high-performance material from the photopolymer product family leads to impact-resistant and at the same time tough components from the 3D printer. The combination of properties qualifies Infinam TI 3100 L to a new standard for additive manufacturing using photopolymer 3D printing processes such as DLP and SLA. The impact strength value measured on printed components is 30 J / m³ with a high elongation at break of 120%.

The new material can thus strong sudden or permanent mechanical effects such as Pressing or pushing withstand very well. The range of possible applications extends from components for Manufacturing, Automotive engineering and consumer goods, which, in addition to design-free shapes, require strong mechanical loads in property use. 

High temperature photopolymer

The photopolymer Infinam ST 6100 L. falls under the category of high-strength synthetic resin. With a tensile strength of 89 MPa, a bending stress of 145 MPa and an HDT of 120 ° C, it fills the material gap in ultra-high-strength photopolymers. This material is therefore suitable for applications that require high temperature resistance combined with high mechanical strength. 

---

Plastic recycling from and for industry

---

“With Infinam TI 3100 L and ST 6100 L photopolymers, we are bringing our first photopolymer materials for additive manufacturing to market maturity. In doing so, we draw on the enormous chemical knowledge of our researchers in the development of ready-to-use formulations. On this basis, we can offer the market unique products with excellent properties and help our customers conquer new areas of application," says dr Rainer Hahn, Head of the Photopolymers Market Segment at Evonik.

High temperature polyamide Luvocom 3F PA for 3D printing

07.07.2020 | The high-temperature polyamide Luvocom 3F PA was specially designed for extrusion-based 3D printing such as FFF. The filament of Lehvoss shows optimized printability and mechanical properties comparable to PA 6 with simultaneously reduced water absorption and higher temperature resistance.

The flame-resistant Luvocom 3F PA KK 50056 BK FR has exceptional properties. Ceramic additives increase thermal stability without negatively affecting processing. With halogen-free flame retardant equipment, UL-94 V0 is achieved for wall thicknesses ≥0,4 mm - with 3D printed test bars. The 3D printer for the test rods came along Ultimaker S5 used in conjunction with a CC 0.6 printer. The corresponding pressure profile is available on the Cura Marketplace for the Ultimaker S5 and soon also for the Ultimaker S3. Material and filament can also be used on other printers.

Due to its electrical insulation properties, the material is suitable for applications in Electrics and electronics and wherever flame resistance is important. The material does not require a heated pressure chamber. Components can be printed without distortion. HIPS and PVOH can be used as support materials.

Aluminum alloy for aircraft components

01.09.2020 | Honeywell and SLM Solutions present a great success as part of their development partnership for the qualification of aluminum components with higher layer thicknesses. Newly developed parameter sets for the aluminum alloy F357 lead to significantly improved material properties.

To the post

---

Filaments for 2-component 3D printing in one step

22.06.2020/3/XNUMX | “More and more designers have asked us in recent years whether it is possible to XNUMXD print components made of several plastics in order to achieve special properties," says Tom Krause, Head of Additive Manufacturing at igus. With 2-component 3D printing (2K), e.g. B. Combine tribo filaments with carbon fiber reinforced filaments. The result is not only a particularly low-wear component, it is also extremely resilient.

To the post

 

Liquid materials for industrial liquid additive manufacturing

10.03.2020/XNUMX/XNUMX | For liquid additive manufacturing offers Delo new possibilities with the further development of its liquid materials. These high-performance materials are transparent or flexible and can be combined in one printing process. In addition, they adhere reliably and have isotropic strength in all directions of pressure. The liquid materials are particularly suitable for 3D printing in automotive and Microelectronics. Delo has made these high performance materials especially for industrial 3D Print further developed. These light-curing Epoxy resins are tailor-made and are made available on the basis of a broad product portfolio.

Good combinability of the liquid materials

Due to the similar chemical basis, the functional liquid materials can be used for the Liquid additive manufacturing combine very well with each other and show good adhesion to each other. This makes them ideal for the material mix. For example, hard and flexible materials can be used in one printing process. In the 3D printer several dosing heads are installed, which apply the respective liquid materials according to defined parameters. Depending on the dosing equipment, structures with wall thicknesses of less than 500 µm are possible. For complex structures with overhangs or undercuts, users can use a water-soluble support material.

---

3D printer for additive manufacturing

---

The Dose the functional materials take place at room temperature. It is therefore not necessary to warm up the material or installation space. Curing takes place using UV light, with a few seconds being sufficient to achieve the final strength. This ensures a simple process and energy savings.

Archive for 3D printing materials news

• 3D printing material with self-extinguishing properties
• Photopolymer for high-precision 3D printing at over 250 °C
• Flexible material based on PU for detailed 3D printing
• Polypropylene for 3D printing of robot grippers
• 3D printing replaces elaborate investment casting
  
  

3D printing material with self-extinguishing properties

11.06.2019 | Mark3D presents the new self-extinguishing material “Onyx FR”. Markforged developed the flame retardant material, which can be reinforced with a variety of continuous fibers, opening up new areas of application in the aerospace, defense and automotive industries.

Onyx FR has a V-0 approval and is therefore different from conventional materials used for additive manufacturing. The usual 3D printed plastics burn, whereas Onyx FR is self-extinguishing. The components that are manufactured with Onyx or Onyx FR offer enormous stability, very good print quality and a high-quality surface. When reinforced with continuous carbon fibers, these components are as strong as aircraft-grade aluminum at half the weight.

Onyx FR complements Markforged's broad portfolio of industrial metal and Composites. Markforged's cloud-based software platform, Eiger, makes it easy for customers to design a part, choose their materials and simply print from anywhere. Onyx FR will now be available to all new and existing Markforged customers with an X-Series 3D printer.

Photopolymer for high-precision 3D printing at over 250 °C

26.09.2018/3/XNUMX | A combination of high manufacturing accuracy and good material properties is required, especially for the XNUMXD printing of plastic injection molds. Featuring Hot Lithography Technology cubicure a stereolithographic process, which processes viscous photopolymers with great precision at greatly increased structuring temperatures of up to 120 °C.

Operating temperatures from above 250 ° C as with injection molds, pose a major challenge for many additively manufactured plastic components. Current solutions are particularly limited in terms of service life and longevity and can therefore only be used to a limited extent for production purposes. With hot lithography technology, high-precision additively manufactured components can be manufactured from heat-resistant photopolymer.

The high printing temperature enables the use of high-viscosity chemical building blocks that have not previously been stereolithographically processable, which significantly expands the range of materials in 3D printing. The novel photopolymer offers a Strength of >70 MPa and a heat resistance of >250 °C. Other advantages of the new Cubicure material are good chemical resistance and good fire properties. In addition to the production of tools, there are also a wide range of new applications in the electronics, automotive, aerospace and other industries.

Flexible material based on PU for detailed 3D printing

23.08.2017 | creabis is now printing the flexible PU-based material TPU Crea 90A on the Formiga P100 with impressive detail. This laser sintering system is particularly suitable for economical small series and products with complex geometries and small dimensions.

The natural white material Polyurethane base for 3D printing can be built into flexible parts with a pleasant feel and has a shore hardness of 90A. In addition, it is very flexible, impact-resistant and wear-resistant even in the cold. Chemical and aging resistance is good. It reacts well under compressive and tensile deformation and is temperature resistant up to 80 °C.

PU material with an improved surface

Since the building process with Layer thicknesses of 0,1 mm takes place, the components have a significantly improved surface quality. The detail resolution in the range of 0,7 mm is very good. The material can be colored and varnished. With the faster availability than before, the delivery time can be less than three working days. Components made of TPU Crea 90A have the so-called dry grip and are particularly suitable for seals and sealing profiles, bellows and pipe connectors, cladding and intake manifolds as well as parts with rubber-like or soft-touch surfaces.

Polypropylene for 3D printing of robot grippers

05.11.2015 | Lehmann + Voss also develops and sells material solutions for industrial 3D printing under the brand name "Luvosint". This is fundamentally changing the way consumer and industrial goods are produced and marketed. The polypropylene (PP) Luvosint 65-8824 for laser sintering was developed according to the requirements of LMD's robot grippers.

The individual gripper and suction cup solutions of the provider are exclusively via laser sintering manufactured. Luvosint 65-8824 now offers new application possibilities. The low specific density of the polypropylene results in a 10% weight saving compared to PA12, which is an important factor for high-speed robot applications.

The height toughness of the material enables the construction of space-saving compressed air-operated actuators. The material does not absorb moisture and therefore does not become brittle due to dry compressed air. At the same time, microbial growth in food applications is avoided. The extraordinary chemical resistance of the PP also enables robotic applications in aggressive atmospheres or media.

3D printing replaces elaborate investment casting

15.05.2014/XNUMX/XNUMX | Until now, complex components such as impellers could only be manufactured in small quantities using the investment casting process, which was very time-consuming and expensive. It proves that things can be different today Schmolz + Bickenbach Guss Group: Here, the 3D printing technology from Voxeljet is favored for the production of lost models and thus sets benchmarks in terms of cost efficiency and production time.

Investment casting with 3D printed plastic models

Whether in the automotive industry or in mechanical engineering - the manufacture of complex components, including impellers, Transmissionhousing and the like in batch size 1 or in small series should be done quickly and economically. The investment casting process in the classic version shows weaknesses here. In addition Thomas Peipp, head of investment casting at the Schmolz+Bickenbach Guss GmbH site in Ennepetal: “The problem lies in the complex production of the required wax models. This requires expensive injection molding tools and wax presses. The tool costs have a major impact, especially with small series, and result in a very high unit price.”

3D printing technology can help. Plastic models can be produced quickly, precisely and inexpensively on modern 3D printers from the Augsburg-based supplier. This PMMA models can substitute wax models one hundred percent. The production of the plastic models in 3D printing is extremely easy, precise and fast. No tools are required for this Digital printing based on the CAD data of the component. The 3D printer takes over the construction of the model using the adapted print data in the layer construction process.

In record time to the 'lost' model

On the latest printers, the production of a plastic model for a succeeds Francis impeller with a diameter of 500 mm in less than 24 h. The material used is PMMA, which begins to soften at 73 °C and burns without residue at temperatures above 700 °C.

The components are therefore very well suited as investment casting models. The casting specialist has had in-depth experience with the 3D printing of plastic models for several years: "In the past we used the models in the Voxeljet- Have the service center printed. The advantages of 3D printing technology and a constantly increasing volume of orders prompted us to invest in our own printer in 2013.

With our VX1000 we can print components made of PMMA material in our investment foundry in the available space of 1060 x 600 x 500 mm and use them to produce cast parts with a maximum unit weight of 70 kg. This enables us to support our customers even faster and more efficiently,” says Thomas Peipp.

The models are created in layering process: The plastic powder is applied to a construction platform in a thin layer and then selectively printed with a solvent. The solvent leads to a locally limited adhesion of the particles to one another. The desired object is created by applying and printing further layers. The unprinted amounts of powder support the printed structure, so that even complicated free-form surfaces with undercuts can be produced without a support structure.

After the printing process, the finished model is freed from residual particle material and infiltrated with wax. This gives the plastic models a closed and clean surface, which has a positive effect on the quality of the investment casting parts affects.

Plastic models replace waxlings

It doesn't matter whether it's a 3D-printed plastic model or a conventionally manufactured one waxling, further handling is exactly identical. After the incoming inspection and the assembly of the gating system, the first ceramic coatings are applied. Then it goes into the oven. Since the plastic models already soften at 73 °C and shrink in the process, no cracks the ceramic bowl. If the temperatures reach 700 °C and more, the molds burn out completely and without leaving any residue. The one-time use of the model explains why we speak of lost models. 

Before the red-hot steel or aluminum alloys are poured into the shell molds, they have to be blown out. It is not necessary to wash out the molds. After cooling, the shell molds as well as the casting and feed systems are to be removed, sharp edges deburred and any undesirable surface defects eliminated. Finally, non-destructive tests and dimensional checks according to customer specifications are on the agenda.

"Regardless of whether it is a prototype, a one-off or a small series - 3D printing technology enables the simple and cost-effective production of highly complex design and investment casting models in the shortest possible time. A huge advantage for us investment casters and above all for our customers,” concludes Thomas Peipp.

FAQ

What is a filament?

A filament usually refers to a thin wire or fiber made of a specific material. The term is most commonly used in connection with 3D printing material. A 3D printer filament is used to create printed components. It is an elongated spool or roll made of a thermoplastic material such as PLA filament or ABS filament. The filament is inserted into the 3D printer and passed through a heated nozzle where it melts and is then applied layer by layer until the desired object is created. Filaments come in different colors and materials. Besides the above plastics, there are also filaments made of Nylon, PETG, TPU and many other materials like Metal and even wood. Outside of 3D printing, the term filament describes a thin wire or fiber for use in e.g. in electronics, lighting technology or the textile industry.

Which plastics can a 3D printer print?

Among the commonly used Plastics include PLA (polylactide) and ABS (acrylonitrile butadiene styrene). Both offer good printability and stability. PLA is eco-friendly and biodegradable, while ABS has higher strength and resistance to high temperatures. In addition, 3D printers can also process nylon, PETG (polyethylene terephthalate glycol) and TPU (thermoplastic polyurethane) to create objects with flexible or durable properties. Other options include polycarbonate, PVA (polyvinyl alcohol) for supporting structures, and specialty plastics such as metal composite filaments loaded with metal particles. The selection of the appropriate plastic depends on the specific requirements of the printed object, such as strength, flexibility, temperature resistance or even electrical conductivity and much more.

What metals can a 3D printer print?

For some time now, 3D printers have also been able to print metals, which is called Metal 3D Printing or Additive manufacturing with metals referred to as. It uses metal powders that are applied in layers and then fused with a laser or other energy source. The most common metals that can be printed with metal 3D printers are stainless steel, aluminium, titanium and nickel alloys such as Inconel. Stainless steel is widely used and offers good strength and corrosion resistance. Aluminum is characterized by its lightness and high thermal conductivity. Known for its high strength, lightness and biocompatibility, titanium is widely used in medical technology. Nickel alloys such as Inconel offer high resistance to heat, corrosion and fatigue and are often used in the aerospace industry. The is currently more and more coming 3D multi-material printing.

Source: This article is based on information from the following companies: Bieglo, Cubicure, Delo, Evonik, Formlabs, Igus, Lehmann & Voss, Mark3D, Schmolz & Bickenbach, Voxeljet.

Author information