What materials should you consider for functional 3D printed prototypes?
When venturing into the realm of 3D printing for prototype development, selecting the right material is crucial. It's the bridge between a concept and a tangible, functional prototype. Your choice determines the prototype's properties, such as durability, flexibility, and heat resistance. Understanding the characteristics of various materials can guide you to make an informed decision that aligns with your prototype's intended use. Whether you're an engineer testing a new design or a hobbyist bringing an invention to life, grasping the nuances of these materials will empower you to print prototypes that closely mimic the final product.
Polylactic Acid (PLA) is a biodegradable thermoplastic derived from renewable resources like cornstarch, making it an environmentally friendly option. It's the go-to material for beginners due to its ease of use and low printing temperature. PLA is ideal for visual prototypes that don't require mechanical strength or high-temperature resistance. It offers a smooth finish and comes in various colors, which makes your prototypes not only functional but also aesthetically pleasing.
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I totally agree with the description above for PLA. Nevertheless, I will like to add that due to it's less expensive makes it more suitable for beginners and anybody who wants to try out any project even if it will require a more dedicated material like fiber mix. Considering PLA for functional prototype will be that such will not require exposure to high temperature.
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PLA is one of the most affordable, easy to use, easily available 3D printing material in the market. Available in multiple colours PLA is best suited for hobbyists, general prototyping and basic form, fit applications. It’s also the most economical material to work with as it prints at lower temperatures and is less prone to warpage and print failures. PLA in the form of Tough PLA is an easy to print material which has strength similar to ABS. It’s neither heat nor chemical resistant but has better tensile strength.
Acrylonitrile Butadiene Styrene (ABS) is a petroleum-based thermoplastic known for its toughness and impact resistance. Unlike PLA, ABS can withstand higher temperatures and has a higher degree of flexibility, making it suitable for prototypes that require durability. However, it does emit fumes during printing, so proper ventilation is necessary. For functional parts that might experience stress or need to endure tough conditions, ABS is a reliable choice.
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ABS is the most common material that you will come across in your day to day life. Hence if you use ABS in your end use part it’s worth testing out your prototypes or functional tests in this material before you proceed further. ABS is also very tricky to print as it can warp easily. Having a heat controlled chamber always helps. ABS has better strength and heat resistance than PLA and is the go to material for functional applications.
Polyethylene Terephthalate Glycol (PETG) is a variant of the common plastic PET, which is used in water bottles, but with added glycol to prevent crystallization. This results in a material that is easy to print like PLA but has the durability closer to ABS. PETG is also resistant to moisture and chemicals, making it a versatile option for functional prototypes that need to endure various environments or come into contact with different substances.
Thermoplastic Polyurethane (TPU) is a flexible, rubber-like material that's perfect for creating prototypes requiring elasticity and shock absorption. TPU can be stretched and compressed while still maintaining its shape, which is essential for items like seals, gaskets, or protective cases. If your prototype needs to bend without breaking or provide cushioning, TPU could be your material of choice.
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TPU is an elastomer material and is available in various shore hardness. Choose a direct drive FFF printer if you want to print more flexible filaments of TPU. TPU is also available in powder form for SLS technology. TPU parts mimic rubber like properties which can be used in bellows, grips, vibration dampners etc. TPU can also be used to print wearables and insoles.
Nylon, a synthetic polymer, stands out for its strength and resistance to abrasion and chemicals. It's a bit more challenging to print with compared to PLA or ABS, but it's worth the effort for prototypes that need to be exceptionally durable. Nylon's low friction coefficient and high melting point make it ideal for functional parts that will undergo wear and tear, such as gears or hinges.
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Nylon is a functional material which can be used to make snap fits, chemical resistant and strong parts that withstand wear and tear. Nylon is hygroscopic in nature and can be a difficult material to print. Nylon is best used with SLS technology for making functional, lightweight, end use parts. Nylon can also be combined with Carbon fiber or glass fillers to achieve better strength and heat resistance.
For those seeking advanced properties in their prototypes, specialty materials like metal-filled filaments, conductive PLA, or Polycarbonate (PC) offer unique capabilities. Metal-filled filaments can add weight and a metallic look to prints, while conductive PLA allows for the integration of electrical circuits. PC is known for its high-temperature resistance and transparency. These materials are more complex to work with but can open up new possibilities for functionality in 3D printed prototypes.
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If a material like PLA, which is probably the easiest to print, for functional prototypes is a bit too brittle then a ToughPLA can be a better option. It is a bit more ductile and can withstand a bit more flexing before it will eventually break. It is less brittle so a great alternative to PLA for functional prototypes.
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