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Proto Labs 19992016 Proto Labs, Inc., 5540 Pioneer Creek Dr., Maple Plain, MN 55359 USA | 877.479.3680 2
Selecting the Right Material for 3D Printing
Material Selection
However, the material suppliers rarely publish material Generally, one or two material properties
specifications that document the change in properties distinguish an additive material from all others.
from one axis to another, as the data behind these For example, if seeking the average tensile
specifications can vary greatly by material, process and strength of polyamide (PA) 11, a stereolithography
even type of machine. photopolymer maybe be a better option than a
selective laser sintering PA. Conversely, if the heat
By designing for the 3D printing process and adjusting deflection temperature (HDT) of an ABS is needed,
the build orientation, anisotropism or inadequate the best option would be a sintered nylon.
material properties can be overcome. To do this,
leverage the experiences from past projects or that of Recognizing that a few properties will separate
a qualified service organization to fill in the data gaps one material from the others, the recommended
that exist because of the limited material properties approach for selecting a material for 3D printing
data. When performance is critical, also consider is to first define what mechanical or thermal
independent lab testing of additive materials. properties are critical. Then review the material
options to find a fit. With the options narrowed,
While success is dependent on material properties, they review other remaining properties to determine if
are not the only considerations. Each additive material the material will be acceptable for the project.
and build process will also dictate characteristics such
as maximum part size, dimensional accuracy, feature Since 3D printing is unique, a goal of finding a
resolution, surface finish, production time and part perfect match to a cast, molded or machined
cost. So it is advised to select a suitable material and material is ill-advised. Instead, investigate the
then evaluate its ability to meet expectations and material options to find the material that satisfies
requirements related to time, cost and quality. the most critical requirements.
Proto Labs 19992016 Proto Labs, Inc., 5540 Pioneer Creek Dr., Maple Plain, MN 55359 USA | 877.479.3680 3
Selecting the Right Material for 3D Printing
the grain structures, which can change with the DMLS 130 ksi
Cobalt Chrome
laser parameters, post-build heat treatment and hot
DMLS
isostatic pressing. However, the results are not widely Inconel 718
180 ksi
available. Ultimately, this difference will become an DMLS
advantage when grain structure can be manipulated 129 ksi
Titanium
to offer varying mechanical properties in a part. DMLS
190 ksi
SS 17-4
Chart 1
Proto Labs 19992016 Proto Labs, Inc., 5540 Pioneer Creek Dr., Maple Plain, MN 55359 USA | 877.479.3680 4
Selecting the Right Material for 3D Printing
elongation at break is significantly lower (1% vs. 11%) when Wrought Metal 10%
Ti 23
compared to the average for 3000 series aluminums.
Wrought Metal 5 7%
17-4 Machined
DMLS titanium (Ti-64 ELI) is most commonly used Wrought Metal 56%
for aerospace and defense applications due to its 316 Machined
strengthto- weight ratio, temperature resistance and acid/
corrosion resistance. It is also used in medical applications. 0% 20% 40% 60% 80% 100%
Versus Ti grade 23 annealed, the mechanical properties
PERCENT
are nearly identical with a tensile strength of 130 ksi,
elongation at break of 10% and hardness of 36 HRC.
Chart 2
Proto Labs 19992016 Proto Labs, Inc., 5540 Pioneer Creek Dr., Maple Plain, MN 55359 USA | 877.479.3680 5
Selecting the Right Material for 3D Printing
Cobalt chrome (CoCr) is one of two DMLS superalloys DIRECT METAL LASER SINTERING
that tend to be used for specialty applications in aerospace HARDNESS
and medical. CoCr has an exceptional EB (20%), and
it is creep and corrosion resistant. Versus ASTM F-75 MATERIAL
CoCr (dependent on heat treating), DMLS CoCr offers DMLS
moderate material properties (DMLS vs. F-75): tensile 25 HRC
Cobalt Chrome
strength of 130 ksi vs. 95-140 ksi, EBof 20% vs. 8-20%, DMLS
35.5 HRC
Inconel 718
yield strength of 75 ksi vs. 65-81 ksi, and hardness of DMLS
25 HRC vs. 25-35 HRC. Of all DMLS metals, CoCr has 39 HRC
Titanium
the best biocompatibility which requires additional DMLS
40 47 HRC
SS 17-4
biocompatibility processing outside of Proto Labs making Wrought Metal
it ideal for medical applications such as dental implants. IN718
36 HRC
Wrought Metal
Ti 23
36 HRC
Inconel 718 (IN718) is a nickel chromium superalloy Wrought Metal
used in high service temperature applications, such as 17-4 Machined
35 45 HRC
aircraft engine components. DMLS IN718 parts have Wrought Metal 25 35 HRC
F75 CoCr
an impressive operating temperature range of -423F
to 1,300F coupled with excellent corrosion resistance, 0 20 40 60
and good fatigue, creep and rupture strength.
ROCKWELL HARDNESS - HRC
DMLS IN718 has higher tensile strength (180 ksi vs. 160
ksi) and comparable yield strength (133 ksi vs. 160 ksi)
than conventionally processed IN718. However, its EB is half MATERIAL
that of conventionally processed IN718 (12% vs. 25%). DMLS 47.2 HRB
Aluminum
DMLS
76.5 101 HRB
SS 316
Wrought Metal
40 50 HRB
Die-cast AL
Wrought Metal 81 HRB
316 Machined
40 60 80 100 120
Chart 3
Proto Labs 19992016 Proto Labs, Inc., 5540 Pioneer Creek Dr., Maple Plain, MN 55359 USA | 877.479.3680 6
Selecting the Right Material for 3D Printing
Selective Laser Sintering Generally, SLS PAs, when compared to the average values of
their injection-molded counterparts, have similar HDT values
DuraForm HST Composite is a fiber-filled PA that is
similar to a 25% mineral-filled PA 12. The fiber content
SLS uses thermoplastic powders, predominantly polyamide but lower values for the mechanical properties. The exception in HST significantly increases strength, stiffness and HDT.
(PA), to make functional parts that have greater toughness is the fiber-filled DuraForm HST composite, which exceeds Compared to other SLS and SL options (excluding ceramic-
and higher impact strength than parts produced through SL, a mineral-filled PA 12 in all areas except tensile strength. In filled materials), HST has the highest tensile strength, flexural
as well as high HDTs (351F to 370F). The tradeoffs are that a few instances, SLS PAs report properties that document modulus and impact strength, and it maintains an elevated
SLS lacks the surface finish and fine feature details available the degree of anisotropism. For a visual comparison of HDT. This makes HST a great choice for functional applications
with SL. SLSmaterial properties, see Chart 4 for heat deflection, Chart where temperatures exceeding 300F may be present. The
5 for elongation at break and Chart 6 for tensile strength. material is somewhat brittle, however, with an EB of 4.5%.
Also consider that like injection-molded fiber-filled materials,
there is a significant delta in the Z-axis values.
DEGREES IN FAHRENHEIT
Chart 4
Proto Labs 19992016 Proto Labs, Inc., 5540 Pioneer Creek Dr., Maple Plain, MN 55359 USA | 877.479.3680 7
Selecting the Right Material for 3D Printing
0 10 20 30 40 50
Charts 5 & 6
Proto Labs 19992016 Proto Labs, Inc., 5540 Pioneer Creek Dr., Maple Plain, MN 55359 USA | 877.479.3680 8
Selecting the Right Material for 3D Printing
Stereolithography
SL uses photopolymers, thermoset resins cured with STEREOLITHOGRAPHY
ultraviolet (UV) light. It offers the broadest material
MATERIAL HEAT DEFLECTION
selection with a large range of tensile strengths, tensile
and flexural moduli, and EBs. Note that the impact Accura 5530 131 482
strengths and HDTs are generally much lower than
those of common injection-molded plastics. The range Accura 60 118 131
of materials also offers options for color and opacity.
Somos Nano Tool 185 437
Combined with good surface finish and high feature
resolution, SL can produce parts that mimic injection PC (Molded) 250 280
molding in terms of performance and appearance.
RenShape 7820 125
The photopolymers are hygroscopic and UV sensitive,
MicroFine Green 122 138
which may alter the dimensions and performance
of the part over time. Exposure to moisture and UV Somos Watershed 115 130
light will alter the appearance, size and mechanical
properties. For a visual comparison of SL material ABS (Molded) 185 215
properties, see Chart 7 for heat deflection, Chart 8 for
Accura Xtreme White 108 117
elongation at break and Chart 9 for tensile strength.
Somos 9120 126 142
Accura Xtreme White 200 is a widely used SL material.
In terms of flexibility and strength, it falls between PP (Molded) 124 203
polypropylene and ABS, which makes it a good choice for
SLArmor
snap fits, master patterns and demanding applications. 10% Metal Volume
122 516
Xtreme is a durable SL material; it has a very high SLArmor 122 516
impact strength (1.2 ft.-lb./in.) and a high EB (20%) 20% Metal Volume
Chart 7
MOLDED MATERIAL COMPARISON KEY
POLYCARBONATE ABS POLYPROPYLENE METAL
Proto Labs 19992016 Proto Labs, Inc., 5540 Pioneer Creek Dr., Maple Plain, MN 55359 USA | 877.479.3680 9
Selecting the Right Material for 3D Printing
PERCENT
Chart 8
MOLDED MATERIAL COMPARISON KEY
POLYCARBONATE ABS POLYPROPYLENE METAL
Proto Labs 19992016 Proto Labs, Inc., 5540 Pioneer Creek Dr., Maple Plain, MN 55359 USA | 877.479.3680 10
Selecting the Right Material for 3D Printing
0 10 20 30 40 50
Chart 9
MOLDED MATERIAL COMPARISON KEY
POLYCARBONATE ABS POLYPROPYLENE METAL
Proto Labs 19992016 Proto Labs, Inc., 5540 Pioneer Creek Dr., Maple Plain, MN 55359 USA | 877.479.3680 11
Selecting the Right Material for 3D Printing
Conclusion
Spanning metals, thermoplastics and thermosets, 3D printing provides many different
materials that can simulate, if not replace, those that are processed through conventional
means. While an exact match is not possible, since the fundamental processes are
different, the material breadth means that there is a strong likelihood that the important
material characteristics are satisfied.
The key to success is being open to, and cognizant of, the differences. With the support
of an informed, qualified 3D printing resource that can fill in the data gaps, this mindset
opens the door to leveraging the unique advantages that 3D printing technology can offer.
>>Sources:
matweb.com, ulprospector.com, vendor datasheets and protolabs.com.
Proto Labs 19992016 Proto Labs, Inc., 5540 Pioneer Creek Dr., Maple Plain, MN 55359 USA | 877.479.3680 12
Selecting the Right Material for 3D Printing
Aluminum
LIGHTWEIGHT
Titanium Ti-6-4
Cobalt Chrome Inconel
TS: 896 MPa TS: 1,240 MPa
TEMPERATURE Inconel 718 Elongation: 20% Elongation: 12%
RESISTANCE Titanium Ti-6-4 Hardness: 25 HRC Hardness: 35.5 HRC
Proto Labs 19992016 Proto Labs, Inc., 5540 Pioneer Creek Dr., Maple Plain, MN 55359 USA | 877.479.3680 13
Selecting the Right Material for 3D Printing
Accura 5530
RenShape 7820 SLArmor Somos 9120 TEMPERATURE Somos NanoTool
Similar to: ABS Similar to: Die-cast Aluminum Similar to: PP RESISTANCE DuraForm HST Composite
PA 615-GS
HD: 122F EB: 0.9-1% HD: 126-142F
EB: 9-14% TS: 100-200 MPa EB: 15-25%
TS: 39-51 MPa TS: 30-32 MPa
Accura 60
HIGH RESOLUTION MicroFine Green
Somos 9120
KEY HD EB TS
RenShape 7820
COLOR MicroFine Green
HEAT ELONGATION TENSILE PA 850 Black
DEFLECTION AT BREAK STRENGTH
Proto Labs 19992016 Proto Labs, Inc., 5540 Pioneer Creek Dr., Maple Plain, MN 55359 USA | 877.479.3680 14