Materials used in AM

 There are many materials that can be used in Additive Manufacturing technologies such as polymers,
ceramics, metals, nylon, ABS, photopolymer resin etc.
 Below are mentioned a few of the most commonly used materials in Additive Manufacturing, its
advantages and disadvantages
 NYLON
 Nylon or Polyamide is a synthetic thermoplastic material, commonly
known as plastic. It was initially created as a replacement material for
silk. Nylon is inexpensive and considered as one of the strongest
thermoplastic materials in the world.
 It is used to create very complex geometrical structures. Due to the high
flexibility, durability, low-friction, and corrosion-resistance features,
 Nylon is widely used in different additivesmanufacturing projects such as
prototyping, modeling, and even footwear and accessories.
 Nylon requires a high temperature to print, and it is harder to get Nylon
to stick to the print bed compared to other
 materials. Nylon is primarily used in Selective Laser Sintering (SLS) or
Fused Deposition Modelling (FDM) and Fused Filament Fabrication (FFF)
printers.
 Advantages:

  Nylon is highly durable and flexible.

  Good replacement for injection molding applications
  Nylon has great mechanical properties and can be used for a
range of applications.
  Nylon can be easily colored, dyed, tumbled and smoothed.
Disadvantages:
  Due to the temperature difference, there can be some shrinkage in
the material.
 Disadvantages

  Due to the temperature difference, there can be some shrinkage in the

material.
 Post-processing can be challenging for SLS parts if you’re not familiar
with the correct steps
  Long cool down cycles limit the productivity
  FDM & FFF nylon filament requires proper drying to achieve the best
results.
2. ABS

 ABS filament is one of the most common filaments used in 3D printers.

 It contains elastomers, which makes the material more flexible and shock-
resistant.
 ABS is most used in car bodyworks, home appliances, and mobile phone
cases. ABS is a durable material and can withstand the temperature
between -4°F to 176°F.
 Along with the high strength, it is a recyclable material and can be used in
chemical processes.
 However, ABS is not a biodegradable material and can shrink in contact
with moist air. It cannot be used in open platform 3D printers;
 The Printing platform must be closed and heated to prevent warping and
shrinkage
Advantages:

  Most readily available and low-cost material

  ABS has a longer lifecycle compared to Nylon
  ABS comes in different colours.
  ABS is highly efficient in creating prototypes and models.
Disadvantages

  Need a closed platform to prevent warping.

  ABS is non-biodegradable. So, it is challenging to get rid of.
  ABS releases toxic fumes and smell at high temperature.
3. Photopolymer Resin
 Resin is one of the most popular 3D printing material out there.
 Resins are UV light-sensitive, and they work by using a light source or laser to
solidify the resins.
 Photopolymer resins are used in technologies like SLA, DLP, MultiJet, and CLIP
technologies.
 Resins are used in creating intricate details with smoother surfaces. The
difference between FDM filament and resins is that you cannot mix different
resins to get different results.
 There are different types of resins for different needs. More durable resins are
used in engineering applications, flexible resins are used in footwear, etc.
Advantages
  Resin can be used in a multitude of applications
  It doesn’t shrink like other polymer materials
  Resins have high chemical resistances
  Resin can be used to produce intricate designs and a smoother
surface finish.
 Disadvantages

  Resins can be expensive

  Resins are photo-reactive. So, you have to be careful when
storing resins
  High heat can cause premature polymerization.
4. Polylactic Acid (PLA)

 PLA, also known as polylactic acid, is a biodegradable material.

 It is created using organic raw material like corn starch.
 PLA is one of the easiest 3D printing material as it doesn’t need any
heated platform to print, and PLA also prints at a lower temperature
than ABS.
 With a high cooling and solidification speed, it’s difficult to manipulate
with the design. Also, the PLA models can deteriorate if it comes in
contact with water.
 The simplicity, the variation of colors, and the properties of PLA make it
the best material to use in FLA 3D printing
Advantages:

  PLA is easier to print

  PLA is available in a wide range of colors
  PLA can be used to print sharp aged designs.
Disadvantages:

  PLA is vulnerable in high heat. It deforms when exposed to high

temperature
  The materials created with PLA are not sturdy.
5. PET/PETG Polyethylene
terephthalate
 PETG or PET is commonly seen in disposable plastic bottles.
 Due to higher chemical resistance and rigid compositions, PET is used in
manufacturing plastic containers used in packaging food.
 PET is a translucent filament with different variations such as PETG,
PETT, and PETE. The general temperature of the printing PET is 167°-
194°F.
 PETG or glycolysis polyester is a variation of PET and the most
commonly used PET in the additive manufacturing market.
 It is an amorphous and recyclable plastic with the characteristics
combined of PLA and ABS.
Advantages:

  PET is a strong, durable and recyclable material

  It can be sterilized to use in the food packaging industry  Its
temperature resistance and easy to print.
Disadvantages

 The material reacts to UV light and may weaken the material

  PET is prone to scratching.
6. Flexible Material (TPU)
thermoplastic polyurethane
 6. Flexible Material (TPU) Flexible filaments made out of TPU or
thermoplastic polyurethane is also a very popular choice as a 3D
printing material.
 TPU is characterized by high flexibility and durability, combining the
properties of rubber and thermoplastics. Because of its chemical
composition,
 TPU is a varied polymer and provides a wide range of use cases. In the
manufacturing industry,
 TPU is generally used to create footwear soles; in the automotive
industry, it is used to create tires and shock absorbers. Also, TPU is
widely used in mobile phone cases and protective covers for intricate
devices.
Advantages:

  Allow manufacturers to create deformable objects

  High impact strength and shock absorbant capabilities
  Have rubber-like elasticity
  Have resistance against oil, grease, abrasion
 Disadvantages:

  Some grades of TPU have a shorter shelf life

  TPU is not as cost-effective as other options
Metals
 1) Stainless Steel

 Stainless steel is known for its high strength and excellent corrosion
resistance abilities.
 Stainless steel is used in various sectors, from manufacturing to
assistive technologies.
 The 3D printing technologies used to print stainless steel are fusion and
laser sintering. Similar to gold and silver, DMLS or Direct Metal Laser
Sintering and SML technologies are used in printing stainless stee
 Advantages:
  Stainless steel is corrosion resistive and high in strength.
  Stainless steel has a high ductility.
 Disadvantages:
  Printing with stainless steel is expensive.
  It takes too much time to 3D print using stainless steel.
 2. Titanium
 Titanium is a strong, lightweight, heat, and chemical resistant material
mainly used for high-performance applications, such as spaceships,
aircraft, and the medical field.
 Due to its high strength, it is incredibly challenging to the machine by
tools. That makes it an excellent material for additive manufacturing.
 Advantages:
  It can create sophisticated products.
  It offers an industrial-grade precision in the design.
  It’s biocompatible and corrosion-resistant
 Disadvantages:
  Titanium is expensive, and the 3D printing process is costly as well
 3. Alumide
 Alumide is a 3D printing material made by mixing polyamide and aluminum
powders using the SLS process.
 Alumide has a porous and metallic finish and has good mechanical strength and
temperature resistance(up to 340 °F). And for these reasons, it’s used in the
rapid prototyping and 3D printing industry.
 It’s used in creating complex modeling, designing, or production of small
functional models that need high rigidity. However, Alumide has some design
limits.
 Advantages:
  Alumide is abrasion resistant
  It’s extremely detailed and clean to print
  It features a high heat resistance and high breaking strength
 Disadvantages:
  Very rough surface
  Not waterproof
  It has design limits.
High Impact Polystyrene

 High impact polystyrene or high-density polyethylene is a lightweight

and flexible material.
 It is widely used in making pipes and plastic bottles and packages due
to its high molding ability.
 HIPS is used as a replacement for ABS because it has high-temperature
resistance, and it is resistant to most of the chemicals except limonene.
However, HIPS requires a heated printing bed to print, and it also shrinks
when it cools down, leading to war page.
 Advantages:
  HIPS is excellent for making intricate designs
  It’s water-resistant  It is inexpensive
 Disadvantages:
  At high temperature, it produces strong fumes
  It solidifies quickly and may clog the printer nozzle if there isn’t
enough heat flow
Aluminium Metal Additive Manufacturing
Materials

 Aluminium (AlSi10Mg)
 Aluminium (AlSi10Mg) was among the first metal additive manufacturing
materials to be qualified and optimised for 3D printing.
 It is well-known for its toughness and strength. It also has an excellent
combination of thermal and mechanical properties, as well as a low
specific weight.
 Applications of Aluminium (AlSi10Mg) metal additive manufacturing
material is in aerospace and automotive production parts.
 Aluminium (AlSi7Mg0.6)
 Aluminium AlSi7Mg0.6 offers good electrical conductivity, excellent
thermal conductivity and good corrosion resistance.
 Applications of Aluminium (AlSi7Mg0.6) metal additive manufacturing
material is in prototyping, research, aerospace, automobiles, and heat
exchangers
Aluminium (AlSi9Cu3)

 AlSi9Cu3 is an aluminum-, silicon-, and copper-based alloy.

 AlSi9Cu3 is used in applications requiring good high temperature
strength, low density, and good corrosion resistance.
 Applications of Aluminium (AlSi9Cu3) metal additive manufacturing
material is in prototyping, research, aerospace, automobiles, and heat
exchangers.
Cobalt Chrome (UNS R31538 / ASTM F75)

 This is a very popular variant of the Cobalt Chrome metal additive

manufacturing material.
 It is a superalloy with excellent wear and corrosion resistance.
 It also showcases great mechanical properties at elevated temperatures,
wear resistance, corrosion resistance, and biocompatibility making it
ideal for applications like surgical implants and other high-wear
applications including in aerospace production parts.
Nickel Alloy (Inconel™ 718 / UNS N07718)

 This superalloy exhibits excellent yield, tensile, and creep-rupture

strength at high temperatures.
 Its superior properties allow engineers to use the material for high
strength applications in extreme environments, such as in the aerospace
industry for turbine components that are regularly subjected to high
temperature environments.
 It also has superior weldability when compared to other nickel-based
superalloys
Copper Metal 3D Printing
Materials
 Copper has long been a sought-after metal additive manufacturing
material. For a long time,
 it was impossible to 3D print copper, but now several companies have
succeeded in developing copper variants for use in various types of
metal additive manufacturing systems.
 Copper fabrication is notoriously difficult, time-consuming, and costly
using traditional methods.
 Most of the challenges are eliminated by 3D printing, which allows users
to print geometrically complex copper parts with a simple workflow.
 Copper is a soft, ductile metal that is most commonly used for its electrical
and thermal conductivity.
 Because of its high conductivity, copper is an ideal material for many heat
sinks and heat exchangers, power distribution components such as bus bars,
manufacturing equipment such as spot welding shanks, antennae for RF
communications, and other applications.
 Copper
 A high purity copper delivers good electrical and thermal conductivity and is
suited for a wide range of applications.
 Copper’s material characteristics makes it ideal for heat exchangers, rocket
engine parts, induction coils, electronics as well as any application requiring
good conductivity like heat Sinks, welding arms, antennae, complex busbars,
etc.
 Gold and silver

 Today, it is possible to 3D print using gold and silver. These filaments are
sturdy materials and are processed in powder form. These materials are
generally used in the jewellery sector. These metal use the DMLS (Direct
Metal Laser Sintering) or SLM process for printing.
 Distinct Characteristics:
 It has high electrical conductance.
 It is heat proof.
 Disadvantages:
 Printing with gold and silver are expensive.
 It takes a lot of effort and time to get it right.
 Both gold and silver are difficult to work with lasers because of its high
reflectivity and high thermal conductivity.
 Since extremely high temperature is needed to print these materials, a
regular FDM 3D printer is not
 Ceramics

 Ceramics is one of the newest material that is used in 3D printing.

 It is more durable than metal and plastic since it can withstand extreme
heat and pressure without even breaking or warping it. Moreover, this
type of material is not prone to corrosion like other metals or wear away
like plastics do.
 This material is generally used in Binder Jetting technology, SLA
(Stereolithography) and DLP (Digital Light Processing).
 Distinct characteristics:
 It has high-precision components with a smooth and glossy surface.
 It has also resistance to acid, heat and lye.
 It has a wide range of colour
 Disadvantages:
 Ceramic requires great amount of temperature to melt.
 It is not suitable for glazing and kilning processes.
 Since it is fragile, it has limitations in printing objects with enclosed and
interlocking parts.
 It is not ideal for piece assembly process.
 Glasses

 Printers use a range of different glass types depending on the desired

final product.
 The most common type of glass used in 3D printing is float glass, which
is a sheet of glass that has been floated on a bed of molten tin to create
a smooth surface.
 Other types of glass that can be used include borosilicate glass, which
is a type of glass that is known for its strength and resistance to thermal
shock.
 Oriflame glass and tempered glass are the two types of glass that are
commonly used for 3D printing.
 A tempered glass is one that has been subjected to a process known as
thermal and mechanical deformation to improve its strength.
 Similarly, dissimilar glass has the same thermal resistance as
Borosilicate glass, but it is not as strong
 Borosilicate glass has a high thermal resistance, making it suitable for
high temperature swings. It is also possible to obtain some
professional 3D printer clamps to secure your bed in place. Despite
being quite pricey, Ender 3 stainless Steel Clamps perform admirably.
 Filament made from glass and can be used on any PLA printer capable
of printing PLA.
 Glass Filled PLA filament offers many of the same characteristics as
standard PLA filament, such as low warp, low odor, and no need for a
heated bed or an external filament printer.
 wood

 Depending on the brand, you can find several different types of wood
filament, like bamboo, birch, cedar, cork, ebony, olive, pine, and even
coconut
 Wood-based filaments are typically a composite that combines a PLA
base material with wood dust, cork, and other powdered wood
derivatives. Typically, the filament consists of around 30% wood
particles, but the exact number may vary depending on the brand.
 The presence of these particles gives the 3D printed parts the aesthetics
of real wood.
 This filament is also less abrasive compared to other composite
filaments such as carbon-fiber filled and metal filled, since wood
particles are much softer.
 There are some wood-like filaments on the market that only contain
wood coloring, but no actual wood particles, so these typically have a
very different look and feel..
 wood

 Models in wood are constructed from a brown, very fine, granular

powder made from wood chips. The surface has a sandy, granular look,
and is slightly porous.
 Wood is perfect for complex models, as it allows for interlocking
and moving parts.
 Typically, these are models you put on your desk or on a shelf such as
architectural scale models, figurines and awards.
 The technique used to print wood gives you lots of design freedom,
meaning you can create an object that cannot be realized with
traditional woodworking methods.
 Advantages
 Wood-textured finish is aesthetically appealing
 Does not need any expensive wear resistant nozzles
 Aromatic and pleasant smelling
 Disadvantages
 Prone to stringing
 Smaller nozzles can end up with partial clogs over time
 May require a larger size nozzle
 One of the best things about wood filament that it can give you a print
with a wood-like finish that doesn’t require the complexity, lack of tools,
and lack of skills that are needed for a traditional woodworking project
at a good 3D Printing quote.
 A wood-based filament f is pretty easy to work with since they don’t
tend to shrink or warp, which allows you to maximize the cooling time
while they are printing to produce a stronger build
 The 3D printing technology used for creating molds and cores from sand
is known as Binder Jetting.
 Binder Jetting printers build parts layer-by-layer, using a binder to bond
and strengthen each layer.
 The most common sand materials used in this process are Silica and
Zircon.
Biological Tissues

 “3D Bioprinting” or “bioprinting” is a form of additive manufacturing

that uses cells and biomaterials instead of traditional metals and
plastics to create 3D constructs that are functional 3D tissues.
 These biomaterials are called bioinks, and they mimic the composition
of our tissues. Bioprinting can be applied to a variety of areas including
but not limited to regenerative medicine, drug discovery and
development, and 3D cell culture.

 Multilayered skin, bones, muscle structures, blood vessels, retinal tissue

and even mini-organs all have been 3D printed
 Hydrogels

Hydrogels can be synthesized from natural polymers, synthetic polymers,

polymerizable synthetic monomers, and a combination of natural and synthetic
polymers
 Hydrogels have tailorable material, physical, chemical, and biological
properties, hold great promise for various biomedical applications
 Polymer hydrogels
 A gel refers to a solid jelly-like material that can have properties ranging
from soft and weak to hard and tough. A polymer hydrogel is a 3D cross-
linked network of flexible polymer chains that contains a large amount
of water but retains the properties of solids
 Selection of materials

 When it comes to 3D printing, selecting the right material is crucial for

achieving your desired outcomes.
 The material you choose can significantly impact the object's
functionality, durability, and appearance.
 To make informed decisions and optimize your prints, it is essential to
understand the importance of selecting the correct 3D printing material.
In this section, we will discuss the key factors to consider when choosing
types of 3D printing materials for your projects, so you can achieve your
desired results with confidence.
 Material properties: Every material possesses unique characteristics,
such as strength, flexibility, and heat resistance, which greatly affect the
performance of the final product.
 Opting for a material with suitable properties ensures the printed object
can endure its intended use and environmental conditions.
 Precision and detail: Certain materials are better suited for producing
intricate and detailed designs, while others are more suitable for larger,
less detailed prints.
 Selecting the appropriate material for your project can help you achieve
the desired level of detail and accuracy in your 3D printed objects
 post-processing requirements: Various materials may necessitate
different degrees of post-processing, including sanding, painting, or
polishing. Understanding each material's post-processing needs will
assist you in choosing a material that best aligns with your project's
requirements and available resources.
 Material compatibility: Not all materials are compatible with every 3D
printing technology and extruders. Picking a material that aligns with
your printer's specifications ensures seamless and efficient printing.
 Cost: Material costs can differ significantly, with some being more
expensive than others. Choosing the appropriate material for your
budget can help you manage project expenses without sacrificing
quality.

 Sustainability and environmental impact: Some materials are more

environmentally friendly than others, providing biodegradable or
recyclable options. Selecting a material with a lower environmental
impact can aid in reducing waste and promoting a more sustainable
future.
 Application
 When choosing a material and 3D printing process for your project, you
should ensure that your material corresponds with the certifications
and/or key characteristics needed for the application.
 Dependent on where the part is in the product life cycle, you will have
different durability needs. For example, a concept model may need to
reflect the look and feel of an end product, but doesn’t necessarily need
to have the same durability of an end product.