Fused Deposition Modeling (FDM) 3D printing has revolutionized both product development and low-volume industrial production. Its versatility largely stems from the wide variety of thermoplastic materials available, each with specific properties that make it suitable for particular uses. Correctly choosing the filament based on the part's purpose, the environment in which it will be used, and the printer's capabilities is a key decision in any professional R&D or manufacturing setting.
Below, we explore the main types of FDM materials, their technical characteristics, and the requirements for printing them.
Material selection should not be taken lightly. For industrial or research applications, it is essential to consider:
Material performance: mechanical strength, flexibility, thermal tolerance, or chemical resistance. For example, a prototype exposed outdoors must withstand UV radiation and humidity, while a mechanical part may require high toughness or low friction.
Printer capabilities: the maximum temperature of the extruder and heated bed, whether it has an enclosed chamber, or the type of hot-end are determining factors. Polymers such as polycarbonate or nylon require high temperatures and controlled environments.
Environmental and safety factors: materials like ABS or ASA emit gases that require ventilation or active filtration. Biocompatibility or food-grade use may also be relevant in biomedical or food research settings.
Cost and availability: while PLA or ABS are low-cost and widely available, other technical filaments (such as PEI or reinforced filaments) represent a greater investment, though they offer superior performance in demanding applications.
Polylactic acid (PLA) is the most widely used material in FDM printing. Derived from corn starch, it is easy to print, does not emit unpleasant odors when printed, and is non-toxic. It melts between 190 and 215 °C and can be printed without a heated bed, making it an ideal choice for models and prototypes with low technical requirements. Its rigidity and dimensional stability are good, but its brittleness and low thermal resistance limit it for functional or outdoor uses.
Acrylonitrile Butadiene Styrene (ABS) offers greater toughness and thermal performance than PLA. It is a traditional plastic in the automotive and electronics industries, ideal for housings and parts subjected to impact. It requires a heated bed (~100 °C) and it is highly recommended that the printer has an enclosed chamber to prevent deformation due to thermal shrinkage or warping. Its printing generates styrene vapors, so ventilation is necessary. It allows post-processing with acetone for smooth finishes.
Acrylonitrile Styrene Acrylate (ASA) is similar to ABS, but with key advantages for outdoor environments. Its resistance to UV radiation and humidity makes it perfect for parts exposed to the elements, such as sensor housings or signage components. It requires similar printing conditions to ABS, but with slightly higher temperatures and ventilation. Although it is more expensive, in contexts where outdoor durability is critical, its performance justifies the cost.
PETG (polyethylene terephthalate glycol-modified) combines chemical resistance, moderate flexibility, and good layer adhesion. It prints at medium temperatures (220–245 °C), with low warpage and without emitting harmful vapors, making it an excellent material for mechanical, functional parts, or containers.
Furthermore, within this family, you can also find CPE, a copolyester variant with greater hardness, elasticity, and chemical resistance, ideal for industrial parts that require high mechanical strength in demanding conditions.
Nylon (polyamide), in versions like PA6 or PA12, is exceptionally durable, flexible, and impact-resistant. However, it is highly hygroscopic, absorbing moisture very easily: it must be stored dry and dried before printing. It requires high heated bed temperatures (240–270 °C) and preferably an enclosed or heated chamber. It is ideal for moving parts, gears, or components subjected to fatigue in mechanical or robotic prototypes.
Polycarbonate stands out for its high rigidity even at elevated temperatures. It is one of the most resistant FDM materials, but also one of the most demanding: it needs hot-ends that reach 300 °C, heated beds at over 100 °C, and a printer with a heated or at least enclosed and well-insulated chamber. Its impact and heat resistance make it suitable for functional prototypes in automotive, electronics, or structures subjected to continuous stress.
Lightweight, fatigue-resistant, and chemically inert, polypropylene is used in parts like hinges or chemical containers. Its challenges are bed adhesion and warping, so it often requires specific print surfaces and adhesives. It prints at medium temperatures (220–250 °C) and stands out for its recyclability and low cost, making it useful for designs oriented towards the circular economy.
PEEK and its variant PEKK are advanced thermoplastics used in the aerospace, medical, and energy industries. They withstand service temperatures of up to 300 °C, resist chemical aggression, and offer mechanical properties similar to metal. They require special printers with hot-ends at 400 °C and heated chambers. Their high cost is justified in applications where no other polymer offers the same level of performance.
PEI (like Ultem) maintains its shape at high temperatures (up to 200 °C) and exhibits flame-retardant properties, making it a strategic polymer for electronics, automotive, or aviation. It requires demanding printing conditions and specialized machinery.
Polymer-based compounds (PLA, Nylon, PETG...) reinforced with carbon, glass, or aramid fibers significantly increase rigidity, thermal resistance, and dimensional stability. They are ideal for tooling, structural parts, or prototypes that must not deform. They require hardened nozzles and higher thermal settings.
Filaments loaded with wood fibers, stone powder, or metals produce unique visual finishes and textures. Although they do not achieve the strength of other materials, they are used for conceptual models, tactile prototypes, or artistic pieces. For example, a PLA with wood fibers can be sanded and stained like natural wood.
These materials contain metallic or ceramic powder in a polymer matrix. After printing, the material is thermally decomposed and sintered, creating a real metallic part. They are valuable in jewelry, metallic prototypes, or low-volume production with properties close to cast parts, but require specific sintering furnaces and precise thermal control.
When dealing with complex geometries or specific functions, support materials and functional filaments greatly expand the capabilities of FDM printing. From soluble structures that allow internal cavities to be printed to flexible, conductive, or self-transforming materials, this category of filaments adds value in R&D and technical manufacturing projects.
Polyvinyl alcohol (PVA) and BVOH filaments dissolve in water, allowing support structures to be removed after printing without leaving residue. They are essential for geometries with complex overhangs or internal channels, especially in functional prototypes such as fluid dynamic components. PVA is frequently used with PLA, while BVOH is compatible with materials like ABS or ASA. Since they absorb moisture, they require dry storage and controlled printing conditions (~190–220 °C). They require printers with dual extruders to print both the build material and the support material simultaneously.
HIPS (High Impact Polystyrene) is used as a support material for ABS and ASA, dissolving in limonene, a citrus solvent. It shares mechanical properties with ABS and prints at about 230 °C. It is ideal in industrial dual extrusion setups where water-soluble supports are not desired.
Additionally, HIPS is also used as a lightweight structural material for functional parts, housings, electronics prototypes, or consumer models due to its excellent impact resistance and good printability.
Some filaments are formulated to be removed manually after printing (breakaway), without solvents. There are specific versions that offer better layer separation, less risk of damaging the part, and easier post-processing.
Thermoplastic elastomers, such as TPU and TPE, allow for the manufacturing of elastic, abrasion-resistant, and highly impact-absorbing parts. They print between 210 and 240 °C, at low speeds, and usually work best with direct extruders (without Bowden) to avoid clogs. They are key in creating functional prototypes that simulate rubber parts: gaskets, covers, soles, soft robotic components, among others.
These conductive filaments incorporate additives such as carbon, graphene, or metallic powders to print electrical traces or conductive surfaces directly onto parts. Although they do not withstand large currents (they are resistive), they allow for the integration of basic electronic functions into prototypes without the need for wiring. Some versions exhibit piezoelectric or magnetic properties, expanding their application in sensors, EMI shields, or smart device development.
Developed for casting, these filaments burn out without leaving residue, creating molds ready for pouring. They are widely used in jewelry, dentistry, or customized metallic prototypes. They mimic technical wax and allow for printing fine details that can then be transformed into real metallic parts.
Designed to expand or form porous internal structures during printing, FOAM filaments reduce the weight of parts and improve thermal insulation. Although more specialized, they are used in packaging prototypes, floats, or lightweight damping elements. They require precise flow adjustments and printing conditions.
These are not intended for manufacturing parts, but for preventive maintenance. These cleaning filaments capture internal extruder residue and remove pigment or polymer remnants after printing high-temperature materials. They are indispensable in laboratory or production environments where different materials are frequently alternated.
The industry is moving towards more environmentally friendly solutions. Filaments based on PHA, biomass blends, or recycled PET and ABS offer an alternative to virgin plastic. They maintain similar properties to their standard equivalents and are particularly interesting in projects that prioritize ecological traceability and reduced environmental impact.
Some special formulations of PLA allow printing at significantly higher speeds without compromising quality. These materials are useful when production time is a critical factor, such as in iterative prototypes or short runs. They maintain good layer adhesion and reduce stringing or oozing.
Polymers that respond to external stimuli (heat, humidity, light) open the field of "4D" printing, where objects can change shape after being printed. Although still experimental, they are already applied in self-assembling structures, medical devices, or smart textiles.
These filaments contain additives like PTFE to reduce surface friction, making them ideal for moving parts (bearings, gears). Their smooth surface reduces wear and avoids the need for additional lubrication. They can be printed under similar conditions to PLA, facilitating their adoption.
Selecting the correct material is as important as mastering its printing. Below are some key recommendations:
Controlled experimentation: testing different materials in the laboratory allows identifying the best balance between ease of printing and technical performance.
Consultation of technical data sheets: knowing data such as tensile strength, HDT (heat deflection temperature), or flow index allows anticipating the material's behavior under real conditions.
Verification of certifications: in industrial projects, it may be necessary to ensure that the filament is food-grade, flame-retardant, or biocompatible.
Planned post-processing: some materials allow chemical smoothing (ABS), others respond well to gluing or painting (PLA). The ease of post-processing can influence the choice.
Storage conditions: filaments such as Nylon, PVA, or BVOH must be kept dry. The use of dehumidifiers or sealed boxes prevents failed prints due to moisture absorption.
Classifying filaments into categories—basic, engineering, high-performance, composite, functional, and emerging—allows for more systematic and performance-oriented decisions.
The current ecosystem of materials for FDM printing covers an unprecedented range of mechanical, thermal, chemical, and aesthetic properties. From conceptual prototypes with PLA to aerospace components printed in PEEK, each project can find a material that adapts to its demands.
The key is to understand the intrinsic properties of each polymer, know the printing requirements, and anticipate the functional behavior of the final part. With an informed selection strategy and proper material management, FDM printing becomes a powerful tool for design, validation, and advanced production.
Are you developing a project with specific technical requirements? Our technical team can help you select, prepare, and optimize the use of the most suitable filament. Contact us and discover everything you can manufacture with precision, performance, and reliability.
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