Learn about the common filament materials used in FDM 3D Printing and the capabilities of each. With better understanding of the advantages and limits of each material, find the ideal material for each purpose and tips on how to print and get the best quality from each.

PLA (Polylactic Acid)

Benchy - A Toy Ship Model Made of PLA Source: StlDenise3d

Material Properties:

Material Cost: $20 to $35 per 1kg roll
Melting Temperature: 190-220°C.
Heat Resistance: Up to 50-60°C. Not suitable for summers in Phoenix, AZ.
Cold Resistance: Can become brittle at -10°C or below, as in Siberian winters.
Material Strength: Fairly strong but brittle.

PLA Common Use Cases:

Food Safe? With precautions. Some PLA filaments are marketed as food safe, but it’s essential to verify certifications and adhere strictly to the recommended use. After printing, parts can have micro-grooves that could harbor bacteria, so food-related items should ideally be for single-use or paired with a food-safe sealant.

Industrial Use? Limited. PLA is biodegradable and has a lower temperature resistance compared to other filaments, limiting its application in some industrial scenarios. However, for prototypes or non-load-bearing parts in mild environments, PLA can be suitable.

Safe to Touch? Yes. PLA generally presents no harm upon skin contact and is commonly used for items like toys and wearables.

Toxicity? Non-toxic. PLA is derived from natural materials like corn starch, making it one of the safest filaments for 3D printing. Nonetheless, maintaining good ventilation is always recommended.

Examples: Toys, Prototypes, Models.

Printing Settings & Best Practices for PLA:

Cooling fans and optionally a heated bed (40-60°C).
Utilize tapes or PEI sheets for bed adhesion.
Ensure good cooling for better bridging and overhangs.
Store in a cool, dry place.

Top brands for PLA Filament

Prusa (Prusament)
Hatchbox
Ultimaker
MatterHackers (Build Series)
Proto-pasta

PETG (Polyethylene Terephthalate Glycol)

Plastic Bottles - Most Commonly made from PETG Source: Simplify3D Website

PETG Material Properties:

Material Cost: $25 to $40 per 1kg roll
Melting Temperature: 220-250°C.
Heat Resistance: Up to 75-80°C. Can be challenging in a hot summer in Death Valley, USA.
Cold Resistance: Retains properties to at least -20°C. Suitable for a Moscow winter.
Material Strength: Strong and slightly flexible.

Common Use Cases

Food Safe? Yes. PETG is widely recognized for its food safety. Filaments often adhere to FDA guidelines and can be used for printing items that come into direct contact with food, such as utensils, containers, and cookie cutters. It’s crucial to note that food safety can also depend on the printing process and post-processing, which should avoid crevices where bacteria can accumulate.

Industrial Use? Yes. PETG is known for its durability and strength, making it an apt choice for numerous industrial applications. Components like machine guards, functional prototypes, and production parts can be manufactured with PETG, leveraging its resistance to chemicals and impact.

Safe to Touch? Yes. PETG has a smooth surface finish and doesn’t have sharp or brittle edges when printed correctly. This makes it suitable for producing items that will be frequently handled, such as tool handles, ergonomic grips, or wearable items.

Toxicity? Non-toxic. PETG does not emit harmful gases or fumes during printing, making it safe for environments like schools and homes. Nevertheless, always ensure a well-ventilated printing area to manage even the safest filament emissions effectively.

Examples: Water Bottles, Food Containers, Heat Resistent Containers

Printing Settings & Best Practices for PETG

Heated bed (70-80°C).
Reduced cooling fan speed.
Ensure a level and clean print bed.
Avoid excessive cooling and tune retraction to minimize stringing.
Store or print with a dryer box to manage moisture.

Top Brands for PETG Filament

Prusa (Prusament)
MatterHackers (PRO Series)
Hatchbox
eSUN
Polymaker

TPU (Thermoplastic Polyurethane)

Shoe Soles - Made in TPU for flexible properties Source: Sculpteo Website

Material Properties:

Material Cost: $30 to $60 per 1kg roll
Melting Temperature: 220-250°C.
Heat Resistance: Moderate, up to 80°C. Can become soft in a hot Dubai summer.
Cold Resistance: Maintains flexibility down to at least -20°C. Endures Oslo winters.
Material Strength: Highly flexible and durable.

Common Use Cases

Food Safe? Variable. Depending on the specific TPU filament and its certifications, some can be considered food safe. Always check the filament specifications and certifications to ensure compliance with food safety standards before using TPU for applications like kitchen utensils or food storage solutions.

Industrial Use? Yes. TPU, with its notable flexibility and durability, finds applications in various industries, such as automotive (for producing vibration dampening washers) or consumer electronics (for protective cases). Its capacity to withstand wear and tear makes it suitable for various functional parts in an industrial context.

Safe to Touch? Yes. Given its flexible and soft nature, TPU is often utilized for objects that require a gentle interaction with the human skin, like wearable tech, wristbands, or clothing accessories. It doesn’t cause irritations under normal conditions.

Toxicity? Generally non-toxic. TPU is widely considered safe to print with, presenting a low risk in typical printing scenarios. However, as with all printing, proper ventilation is advisable to ensure a safe printing environment.

Examples: Cases, Shoe Insoles, Wearable Accessories.

Printing Settings & Best Practices

Slow print speed (15-30 mm/s).
Minimal retraction.
Utilize a direct drive extruder.
Adjust extruder tension for optimal feeding.

Top Brands for TPU Filament

NinjaTek (Ninjaflex)
MatterHackers (TPU)
Sainsmart
Priline
OVERTURE

ASA (Acrylonitrile Styrene Acrylate)

Shoe Soles - Made in TPU for flexible properties Source: Fusion3Design Website

Material Properties:

Material Cost: $35 to $60 per 1kg roll
Melting Temperature: 230-250°C.
Heat Resistance: High, up to 100°C. Suitable for summers even in extremely hot climates.
Cold Resistance: Maintains properties to at least -30°C. Durable in Alaska winters.
Material Strength: Strong with good weather resistance.

Common Use Cases

Food Safe? No. ASA generally isn’t certified as food safe and thus shouldn’t be used for items that will come into direct contact with food. Other filaments like PETG or specific PLA might be more suitable for such applications.

Industrial Use? Yes. ASA’s resistance to UV, weather conditions, and its mechanical strength make it an ideal choice for industrial parts exposed to outdoors or harsh environments. Components like UV-exposed drone parts, automotive exterior parts, or outdoor fixtures and fittings are common applications.

Safe to Touch? Yes. ASA does not pose direct harm upon contact, but attention should be paid to the printed part’s geometry and functionality to ensure it is safe to handle and use.

Toxicity? Manage fumes. During printing, ASA can emit fumes that should be managed with adequate ventilation or air filtration systems, especially in non-industrial settings.

Examples: Outdoor Products, Signage, Automotive Parts

Printing Settings & Best Practices

Heated bed (90-110°C) and enclosure.
Slow printing and use a brim for bed adhesion.
Allow gradual cooling post-printing.
Adhesion helpers recommended.

Top Brands for ASA Filament

Prusa (Prusament)
Filamentum
Polymaker
eSUN
Raise3D (Premium ASA)

Nylon

Industrial fasteners, wearables - Made in Nylon for durability resistence and reliability Source: cimquest Website

Material Properties:

Material Cost: $40 to $70 per 1kg roll
Melting Temperature: 240-260°C.
Heat Resistance: Up to 80°C. Not for industrial kitchens but good for general use.
Cold Resistance: Down to -40°C. Good for Ottawa winters.
Material Strength: High strength and durability.

Common Use Cases

Food Safe? Some grades. Specific grades of nylon are deemed safe for food contact, subject to adherence to relevant regulations. Such applications might include utensils, food storage, and certain cooking implements. Ensure that the chosen nylon filament is certified for food contact.

Industrial Use? Yes. Widely acclaimed for its strength and durability, nylon is utilized for various industrial components like gears, fasteners, and durable prototypes. Its resistance to wear and ability to withstand repeated stresses make it popular in manufacturing.

Safe to Touch? Yes. Nylon does not present irritants, but its suitability for skin contact can depend on factors like finish and application. For instance, nylon fabric is widely used in clothing due to its comfort against the skin.

Toxicity? Fumes need managing. Nylon emits caprolactam during printing, which, while not acutely toxic, should be managed with effective ventilation or filtration to ensure a safe printing environment.

Examples: Industrial Clothing, Gears, Mechanical Parts.

Printing Settings & Best Practices

Heated bed (70-100°C) and enclosed chamber.
Ensure thorough filament drying.
Use a raft and/or adhesive materials like garolite for better adhesion.

Top Brands for Nylon Filament

Taulman3D
MatterHackers (PRO Series)
NylonX (Carbon Fiber Nylon)
eSUN (ePA)
Ultimaker

ABS (Acrylonitrile Butadiene Styrene)

Lego Blocks - Commonly made in ABS plastic Source: iStockPhoto Website

Material Properties:

Material Cost: $20 to $40 per 1kg roll
Melting Temperature: 220-250°C.
Heat Resistance: Up to 90°C. May struggle in hot industrial environments.
Cold Resistance: To -20°C, but may get brittle in the frigid winters of Northern Europe.
Material Strength: Strong with some flexibility.

Common Use Cases

Food Safe? Not typically. ABS is not generally considered food safe and should not be utilized for creating items that will contact food directly. A more suitable filament like PETG may be used in these instances.

Industrial Use? Yes. ABS has a commendable balance of strength, toughness, and temperature resistance, making it a favorable choice for industrial applications. Its uses span from creating durable prototypes to crafting functional parts in manufacturing setups.

Safe to Touch? Yes, once printed and cured. ABS objects are safe to handle, but attention must be paid to part design to eliminate sharp edges or points that could pose a risk during interaction.

Toxicity? Styrene fumes require management. ABS emits styrene during printing, which should be managed with good ventilation or in a filtered enclosure to maintain air quality and safety.

Examples: Toys, Automotive parts, Enclosures.

Printing Settings & Best Practices

Heated bed (80-110°C) and printing enclosure are recommended.
Ensure adequate ventilation due to fumes.
Employ adhesion helpers like ABS juice or brims.
Allow for slow cooling to avoid warping.
Possibly anneal for enhanced strength and temperature resistance.

Top Brands for ABS

Stratasys
Hatchbox
eSUN
MatterHackers (PRO Series ABS)
LulzBot

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