In this article we will describe several kinds of plastic for 3D printing. Namely such materials for 3D printer as ABS (acrylonitrile butadiene styrene), PLA (polylactide), PVA/PVAc (polyvinyl acetate) and nylon plastics.
Today, the two main materials on the 3D printer plasticmarket are PLA and ABS plastic. These materials for 3D printer have long established themselves in the market. And are used by printers that create three-dimensional products – with the help of layer-by-layer build-up technology.
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ABS plastic (ABS plastic)
ABS-, aka ABS-plastic – Acrylonitrile Butadiene Styrene – is a plastic whose name is formed from the initial letters of the names of the substances from the polymerization of which it is formed: acrylonitrile(A) with butadiene (B) andstyrene (S). More specifically, butadiene and acrylonitrile-styrene copolymer (SAN).
It takes about 2 kilograms of oil to produce a kilogram of ABS plastic. Some types of such plastic tend to decompose in sunlight, which once even caused a large-scale recall of a batch of cars in the United States.
Plastics such as thermoplastic resin can be recycled. For this reason, packaging made of such plastic that is recyclable is marked with the international recycling symbol, a triangle formed by three black arrows.
ABS material for 3D printing has the following positive characteristics:
- In its “natural” form it has a translucent yellowish tint, but can be dyed in different colors;
- It is inexpensive: on average, twice as cheap as its direct competitor – PLA-plastic;
- Increased impact resistance and elasticity;
- Durable;
- Non-toxic;
- Moisture resistant;
- Resistant to oils, alkali and grease-soluble detergents;
- Heat resistant: it can withstand heat up to 103°C and its modified types up to 113°C;
- Can be reliably operated over a wide temperature range (-40 °C to +90 °C);
ABS plastic is used to manufacture the following products:
- Disposable utensils;
- Sports equipment;
- Cases and parts of various products (machinery, electrical equipment, tools (audio equipment, TVs, telephones, DVD players, tablets, vacuum cleaners, remote controls, monitors, etc.));
- Car spare parts: wheel covers, grilles, bumpers, plastic interior parts (e.g. dashboard), etc..;
- Parts and bodies of products with metallized base (including sanitary equipment (valves, shower diffusers, sinks, trays, cisterns, etc.), metallized decorations, etc.);
- Electrical parts (switches, switches, etc.);
- Stationery and supplies;
- Children’s toys and constructors (e.g., Lego);
- Plastic boxes (household, medical and other types of plastic boxes, organizers, suitcases and containers);
- Plastic furniture, furniture and door hardware;
- Plastic cards (smart cards, bank cards, discount cards, travel cards, ID cards, etc.).
ABS plastic for 3D printer has a number of differences from regular ABS plastic:
- The abs plastic for 3D printer has more durability;
- The prototype made of ordinary abs plastic suffers a slight deformation invisible to the human eye when exposed to a damp atmosphere;
- ordinary abs plastic, which is used, for example, in construction parts, is smooth, but when printed with a 3D printer, prototypes with a rough surface are produced. This disadvantage is easily remedied by light sanding.
ABS plastic has become one of the main materials for 3D printing due to its optimal melting, printing and vitrification (solidification) temperatures, as well as its durability in operation. Under normal operating conditions, under short-term heating (from 40 to 90°C – depending on the brand of plastic), objects made of ABS plastic do not deform!
The melting and printing temperature of abs plastic allows you to work with it in ordinary production shops, without special protective clothing. At the output of the print head, the temperature of such plastic reaches approximately 200-270°C, but the 3-D printer work table itself is heated up to only 110°C.
But, despite the convenience of temperature characteristics of operation, during 3D printing with ABS plastic, there may be a problem of adhesion of particles of such plastic between themselves and with the working surface of the printer. Therefore, for the accuracy of prototype placement during printing, the printer mounting table is heated and covered with a special amber-colored thermal tape – Kapton.
Or the mounting table is lubricated with a solution of plastic on acetone. In this case, the fixation strength of the build-up prototype increases, but the printed 3D model is somewhat more difficult to separate from the work surface. That is, for printing more fragile 3D-objects, it is better to use kapton tape.
When mentioning the mounting table for building prototypes and products, it is impossible not to remind that every 3D printer has limitations on the size of the print object: on the size of the working table and on the height of the working area – up to the base of the structure to which the mechanism with the print head is attached. This property could be attributed to the disadvantages of 3D printing, but it should be taken into account that each 3D printer is created for a certain scale of tasks and needs of the customer.
Therefore,when choosing a 3D printer, you just need to understand what 3D printing goals you will put in front of it. In addition, the problem of limiting the size of the 3D printing object can be solved by printing the object in parts, with further joining of parts with superglue or other similar high-strength adhesives – so-called “cold welding”.
Based on personal experience in 3D printing, industrial and graphic design studio KOLORO can state that when printing large models with ABS-plastic, deformation of the prototype when it cools down is possible. This can be solved by printing a large prototype in parts, or by dividing a large, hollow prototype into several parts that can be glued together.
It is worth considering that ABS-plastic from China, due to its not always high quality, quickly clogs the print head of the 3D printer. Not to mention that during printing Chinese plastic spreads an unpleasant odor. Therefore, if you are reading this article and are going to buy plastic for printing on a 3D printer, think carefully, and make sure that the manufacturer has all the certificates of technological safety.
Despite the fact that we mention China as a country of origin of not very high quality, but extremely popular on the market, plastic for 3D printing, approximately 75% of ABS-plastic is produced in the countries of the eastern region. However, the largest, most respected producers of ABS plastic are not located in China, but in Japan (Techno Polymer), Taiwan (BASF, Lanxess, LG Chemicals, Samsung and Cheil) and South Korea (Techno Polymer).
The rest of the major ABS plastics producers are located in Europe (Italy, Belgium) and Russia. In particular, such large ABS-plastic producers as BASF, Dow Chemicals, Ineos and Polimeri Europe are located in Europe. And in Russia – OAO Nizhnekamskneftekhim (Tatarstan), OAO Plastik (Tula region), DPO Plastik (Moscow region) and some other manufacturers.
Interestingly, as with other major industries, many plastics companies began their active relocation to Asian countries starting in the 80s. This was the case with the USA, the leading producer of ABS plastic in the 80s.
Needless to say, this decision was mainly influenced by the abundance of cheap labor in Taiwan and China! And modern equipment, after a short internship, does not require special skills or professional education to operate an alreadyautomated process. A certain harmfulness of this production in relation to the environment also influenced. As well as the convenience of delivery to these countries of the main raw material for plastic production – oil. And the presence of a huge market for plastic in the eastern countries on a production scale.
Also an important factor of the above statistics is the fact that the leading countries of economic development, such as the USA, Germany, Japan, Switzerland, Finland and others, try to keep only the least energy-consuming production, having long ago made their choice in favor of production technologies. Including those related to the production and recycling of plastic, which is extremely important, given the scale of pollution of the planet by products made of poorly degradable materials.
These countries are actively engaged in such areas as: development of components that contribute to quality recycling and degradation of plastic; work with technologies that make such material impact-resistant, but easily recyclable, etc.
As for the global ABS plastic consumption market, the total consumption share of Europe and the U.S. is about 35%, the rest of the consumption market belongs to the countries in the eastern region of Eurasia (about 60%) and other countries in the world (about 5%).
PLA plastic (PLA plastic)
But, the main competitor of ABS plastic is PLA plastic, a biodegradable plastic – a so-called aliphatic polyester with a monomer in the form of lactic acid. This plastic is called bio-compatible because the main materials for its production are rapidly renewable resources, mainly sugar cane and corn.
In addition,renewable raw materials such as starch (potato starch, corn starch, tapioca (starchy starch from cassava root tubers), soy protein, cellulose,etc.), cellulose andothersaresometimesused to make biodegradable plastics. Those that are not hazardous or toxic in production and after use decompose into carbon dioxide and water or environmentally friendly biomass (composting).
So,the main advantage of PLA-plastic is that it is non-toxic, therefore, it can be safely used for the manufacture of toys and other products that do not carry a direct threat to human health – food plastic, disposable tableware, etc.
PLA plastic has a lower filament softening temperature (about 190°C) than ABS plastic and a printing temperature of 210 to 250°C, which means that working with it is less energy-consuming. In addition, when 3D printing with this plastic, there is no need to use kapton (to lubricate the surface for prototype build-up). And there is no need to heat the table to “peel off” the object that has been built up on it.
Another plus is a fairly smooth surface of the product printed from PLA-plastic, good detailing, easy refinement by grinding or other methods that do not require special equipment.
The disadvantages of PLA plastic for 3D printers include the fact that it is somewhat more expensive than ABS plastic. And the fact that it loses its original quality rather quickly (compared to durable ABS) and is therefore only suitable for manufacturing objects with a limited lifespan. The decomposition period of PLA plastic ranges from a few weeks to several years, depending on the brand.
Conditionally, the disadvantages of PLA-plastic can be attributed to the fact that, unlike ABS-plastic, it is not soluble in acetone. However, pla-plastic is well soluble in phenol, in concentrated sulfuric acid and in a substance called “limonene”.
Regarding the PLA plastic production market. If the main component for ABS plastic production is oil, and the main producers are the countries that have convenient conditions for receiving such raw materials in ports and wide opportunities for production and marketing of ABS products. In the case of PLA-plastic, the situation is somewhat different.
Corn starch and sugar cane are the main raw materials used to produce these plastics. Consequently, the largest raw material markets for plastics are in countries that prioritize the cultivation of these crops. For example, sugarcane cultivation is widespread in tropical and subtropical regions such as Cuba, Brazil and China.
An exotic starchy plant, cassava, from whose roots the raw material for cassava flour is obtained, grows in countries with tropical climates such as Latin America and Africa, as well as in Asia and Indonesia. Here, cassava groats are widely used as a staple food. Thailand is the main supplier of tapioca.
Corn cultivation is most subsidized in the USA, where the largest producers of corn plastic and companies for its processing are located in the Midwest. Since about 2006 there has been an active discussion in the USA about the complete replacement by PLA-plastic of other types of plastic used for the production of disposable tableware and packaging, including for beverages (sodas, drinking water, etc.). However, since the tests conducted on this subject by the largest research enterprises of the USA and Europe have very ambiguous results, this program is not yet launched in full.
That’s all well and good: PLA plastic decomposes within a few years at most when placed in a compost pit. When it is recycled by incineration, it does not produce the harmful contaminants typical of petroleum plastic recycling. And corn can be grown in just 100 days, unlike oil, the composition of which is formed over millions of years! But there are still strong counterarguments from the side of opponents of complete replacement of ABS plastic with PLA.
First: cheap (and “food” plastics are cheaper than their abs counterparts) always leads to more consumption! Secondly: no sorting procedure is in place The PLA marking is not applied to all products. PLA labeling is not put on all goods. And not everyone has the desire to enter into new “sorting games” with waste collectors who prefer not to “bother” with additional sorting.
Thirdly: the proposal to openly decompose such plastic – in compost pits – always draws protests from residents of nearby communities. People rightly believe that PLA decomposition products, which are not fully understood, could end up in drinking water. This may entail environmental consequences no less scandalous than in the case of Nickel Valley (USA), where production waste got into groundwater and led to various incurable diseases in people who somehow use contaminated water. Especially the public fears the consequences of open decomposition of plastic from genetically modified corn!
When PLA-plastic is incinerated, it does not emit harmful impurities, but when decomposing in open compost pits, methane is released into the air, which destroys the ozone layer of our planet. In this regard, puzzled manufacturers, owners of grocery chains and even journalists find nothing better than to advise to use reusable PLA containers as long as possible before throwing them in the garbage.
At the moment, pla-plastic most often becomes the material for the following products:
- Food grade plastic products – airplane tableware, packaging, disposable containers;
- Medical supplies (pins, surgical threads);
But let’s return directly to 3d-printing of products made of pla-plastic. Printing from this material has a number of advantages. And, to the delight of the environment, it does not yet have a scale comparable to the production of disposable tableware.
PLA plastic, as well as ABS plastic, can be used to print wonderful prototypes of products (architectural designs, product details, decorative products, enclosures, etc.). But, when printing with PLA plastic – the products will have a much more finished and detailed look!
It isbetter to print prototypes and products for long-term usefrom ABS plastic . And from PLA-plastic – objects for decorative purposes, as well as products that perform a presentation role and products that require greater detail, for use in a shorter period of time (declared by the manufacturer of the material).
When choosing a method of 3d-printing you need to take into account that PLA-plastic, despite its high density, is more fragile, and after solidification is less amenable to post-processing. Therefore, 3d-model of the product must be well prepared for printing, taking into account all the important features of the geometry of the object. Given the above, many prefer to use for all types of printing ABS-plastic, considering it a universal and alternative material for the manufacture of products with a long service life. And the disadvantage, roughness of the products obtained by abs-printing, can be compensated by post-processing (sanding).
PVA plastic
To be fair, a new type of material for 3D printing has recently appeared on the market – PVA-plastic (polyvinyl acetate). In fact, it is familiar to everyone from school lessons of labor glue PVA, but in this case from a dry state, PVA is diluted with water to a certain consistency. And then, with the help of special equipment, is melted and formed into special granules or pva-filaments for 3D printing. It is too early to talk about this type of plastic and its certain advantages over other materials for 3D printing. It appeared on the market only in 2012.
It is known that PVA plastic is used as a separator for printed parts, due to the fact that it dissolves well in water. Let’s take an example: we print on a 3D printer a part, a nut screwed on a bolt, using PVA plastic and some other plastic (abs or pla). And after printing, we dip the finished prototype of the product for a short time in water, and then easily remove the nut. Thus, with the help of pva-plastic we get several finished products in one printing!
One of the main disadvantages of this material is its high price and solubility in water – in some cases it is useful, but in other cases it is completely unacceptable. Work with PVA plastic takes place at a temperature of 190°C, and its melting point is 160-170°C, its solidification (glass transition) temperature is 45-55°C.
Nylon
Nylon(nylon) is considered to be an even newer material for 3D printing. The material is well resistant to a wide range of solvents and chemicals. Especially popular today is Nylon by Taulman 3d. Nylon is known to be successfully used in various industries:
- In medicine, for bone regeneration and replacement, and for making durable customized prostheses with creative perforation patterns.
- For prototyping products on CNC machines – from printed nylon blocks, or for finalizing already printed nylon prototypes on said machines.
- For printing connecting elements for metal structures.
- In the foundry industry for creating casting molds (not for silicon prototypes), by creating a mold model in stl format to convert a given model into a digital G-code acceptable for 3D printing.
- In the electrochemical industry to create rechargeable polymer battery separators.
- In music (e.g., nylon strings).
To summarize, we can say that the market of materials for plastic printing on 3D printers is constantly expanding. And one can’t help but be pleased by the manufacturers’ desire to make their materials more environmentally friendly, although not without persistent guidance from the state and society.
Follow our publications, and you will be aware of all the most significant novelties in the field of 3D printing! And here we will finish the description of the most popular materials for 3D printing with plastic, and remind you that our designers and technologists can design, visualize and print for you a 3D-object of any complexity!
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