3D Printing and Design (Advance) 3D printing raw materials come in various forms to accommodate the diverse range of 3D

printing technologies and applications. Liquid materials are used in SLA and Material Jetting,
UNIT-1 providing high precision and smooth surface finish. Solid materials, commonly used in FDM,
Syllabus offer versatility and a wide selection of thermoplastics for various applications. Wire-based
3D printing, known as WAAM, is primarily used for metal components, offering advantages
Unit-1.0 3D Printing Materials in terms of reduced waste and faster deposition rates. Powder materials are utilized in SLS
1.1 Various forms of 3D printing raw material-Liquid, Solid, Wire, Powder. and Binder Jetting, providing design freedom and versatility for complex geometries and a
wide range of materials. Each form of raw material has its unique benefits and limitations,
1.2 Popular FDM, SLA, SLS, Binder Jetting, Material Jetting and Direct Energy deposition 3D allowing users to choose the most suitable option based on their specific needs and project
printing materials. requirements. As 3D printing technology continues to evolve, we can expect further
1.3 Polymers, Metals, Non-Metals, Ceramics. advancements in the development of raw materials and their applications across industries.

1.4 Polymers and their properties.

1.5 Powder Preparation and their desired properties. 1.1 Various forms of 3D printing raw material-Liquid, Solid, Wire, Powder.

1.6 Choosing the Right 3D Printing Material on the basis of Performance Requirements and We will explore the four main forms of 3D printing raw materials: Liquid, Solid, Wire, and
Material Properties. Powder.

Liquid Raw Material:

Unit-1.0 3D Printing Materials
Liquid raw materials are primarily used in
Introduction to 3D Printing Materials. 3D printing technologies such as
3D printing, also known as additive manufacturing, is a revolutionary technology that Stereolithography (SLA) and Material
enables the creation of complex three-dimensional objects layer by layer, directly from Jetting. In these processes, liquid
digital models. One of the critical components of 3D printing is the raw material used to photopolymers are transformed into solid
build the objects. Various 3D printing technologies require different forms of raw materials, objects through the use of light or other
each with its unique characteristics and applications. curing mechanisms. SLA, in particular,
relies on a process called
photopolymerization, where a light source
(typically a UV laser) selectively cures the liquid resin, solidifying it layer by layer to form the
final object.

 Definition: Liquid-based 3D printing, also known as "SLA" (Stereolithography) or "DLP"

(Digital Light Processing), uses liquid photopolymer resin as its raw material. This resin
solidifies when exposed to specific wavelengths of light.

 Properties: Liquid resins come in various formulations with different properties such as
flexibility, hardness, transparency, and color. They can create highly detailed and
smooth objects, but they may be brittle and less durable compared to other materials.

 Viscosity: Low viscosity enables smooth printing.

 Curing: They cure quickly under light exposure, allowing for faster production.
 Detail Resolution: Liquid materials offer high detail resolution, ideal for intricate
designs.
 Advantages:  Disadvantages:
a) High detail accuracy and surface finish. a) Limited detail resolution compared to liquid-based methods.
b) Suitable for dental, jewelry, and medical applications. b) Post-processing like sanding may be required for smoother surfaces.
c) Can create transparent objects. c) May require heated print beds or controlled environments.
 Disadvantages:
 Applications: Used for creating prototypes, functional parts, toys, decorations, and
a) Limited mechanical strength compared to other
more.
materials.
b) Limited material variety compared to solid materials.
c) Post-processing often requires additional steps.

 Applications: Used for producing high-resolution

prototypes, intricate jewelry, dental models, and other
applications requiring fine detail.

Solid Raw Material:

Solid raw materials are commonly used in Fused

Deposition Modeling (FDM), one of the most popular
and widely accessible 3D printing technologies. FDM
printers work by extruding a solid filament, usually
made of thermoplastics, through a heated nozzle.
The material is deposited layer by layer, fusing each
layer to the one below it as it cools and solidifies.
 Definition: Solid raw materials for 3D printing
include filament materials like PLA, ABS, PETG, and more. These materials are in solid
filament form and are melted and extruded through a heated nozzle during printing.
 Properties: Filament materials offer a wide range of properties, such as strength,
flexibility, heat resistance, and more. They are relatively easy to use and are commonly
used in desktop 3D printers.
 Variety: Wide range of materials available,
including ABS, PLA, PETG, etc.
 Mechanical Strength: Solid materials offer
good mechanical properties.
 Layer Adhesion: Strong inter-layer bonding.
Wire Raw Material:
Wire-based 3D printing is often referred to as Wire Arc
Additive Manufacturing (WAAM). This technology is used
primarily for metal 3D printing. Instead of using a
filament or a liquid resin, WAAM utilizes a solid metal
wire as its raw material. The wire is fed into a welding or
deposition head, where it is melted and deposited layer
by layer to create the 3D object.
 Definition: Wire-based 3D printing, also known as
"Wire Arc Additive Manufacturing" (WAAM), uses
metal or alloy wires as the raw material. An electric
arc is used to melt the wire, which is deposited layer
by layer to build up the final object.

 Properties: WAAM-produced objects can have excellent mechanical properties due to

the use of metals. They are often used for large-scale industrial applications.
 Advantages:  Material Diversity: Various metals and alloys can be used.
a) Durable and functional prototypes.  Strength: High mechanical strength and durability.Conductivity: Suitable for
b) Suitable for engineering and consumer goods. electrical components.
c) Wide material selection for different applications.
 Advantages: (EBM), use fine powders as raw materials. A laser or electron beam selectively melts
a) Produces strong and durable metal parts. and fuses the powder particles together.
b) Ideal for aerospace, automotive, and medical industries.
 Properties: Powder-based materials offer a wide range
c) Enables rapid prototyping of metal components.
of properties depending on the material used,
including metals, ceramics, and polymers. They can
produce complex geometries and are known for their
 Disadvantages:
strength and durability.
a) Limited precision for intricate designs compared to other methods.
b) Post-processing is often required for surface smoothing and refinement.  Material Diversity: Wide range of metals, plastics,
c) Equipment and setup costs can be high. ceramics, and composites.
 Precision: High level of detail achievable.
 Applications: Commonly used in aerospace, automotive, and heavy industry for creating
 Porosity: Can result in porous structures.
large metal parts like aircraft components, automotive chassis, and more.
 Advantages:
a) Complex geometries and internal structures can be
created.
b) Ideal for rapid prototyping and small-batch production.
c) Suitable for medical implants and dental applications.
 Disadvantages:
a) Powder handling can be hazardous and require controlled environments.
b) Post-processing like sintering is often necessary.
c) Surface finish may require additional steps.

 Applications: Used in aerospace, medical implants, custom prosthetics, and other

applications requiring complex, high-strength parts.

Powder Raw Material:

Powder-based raw materials are utilized in 3D

printing technologies such as Selective Laser
Sintering (SLS) and Binder Jetting. SLS employs
powdered polymers, metals, or ceramics, while
Binder Jetting utilizes powder infused with a
binding agent.

 Definition: Powder-based 3D printing

processes, such as "Selective Laser
Sintering" (SLS) or "Electron Beam Melting"
1.2 Popular FDM, SLA, SLS, Binder Jetting, Material Jetting and Direct Energy deposition  Applications: PETG is suitable for functional parts, containers, outdoor signage,
3D printing materials. and applications requiring durability and some flexibility.

 FDM 3D Printing Materials:

Fused Deposition Modeling (FDM) is one of the most popular 3D printing technologies, and 4. TPU (Thermoplastic Polyurethane):
it uses solid filament materials as its raw materials. Here are some common FDM printing
 Properties: TPU is a flexible and elastic
materials, along with their properties and applications:
filament with rubber-like properties. It
1. PLA (Polylactic Acid): can withstand bending, stretching, and
compression. It comes in varying levels of
 Properties: PLA is a biodegradable and
flexibility.
environmentally friendly material. It is easy
to print with, has low warping, and comes  Applications: TPU is used for producing
in a variety of colors. It has good strength flexible parts such as phone cases, shoe
and is relatively rigid. soles, gaskets, and wearable devices.

 Applications: PLA is often used for 5. Nylon:

prototypes, hobbyist projects, decorative
 Properties: Nylon is known for its strength,
items, and educational purposes. It's not suitable for high-temperature
durability, and resistance to impact. It has good
applications due to its relatively low heat resistance.
layer adhesion and can be more challenging to
2. ABS (Acrylonitrile Butadiene Styrene): print due to its hygroscopic nature (it absorbs
moisture from the air).
 Properties: ABS is known for its toughness,
impact resistance, and higher temperature  Applications: Nylon is used for producing
resistance compared to PLA. However, it can functional and load-bearing parts like gears,
be more challenging to print due to warping brackets, tooling, and prototypes requiring
and fumes emitted during printing. higher strength.

 Applications: ABS is used for functional parts,

automotive components, enclosures, and
SLA 3D Printing materials:
objects that require durability and moderate
heat resistance. Stereolithography (SLA) 3D printing is a process that uses liquid photopolymer resins as its
raw materials. These resins are cured or solidified layer by layer using a UV laser or other
3. PETG (Polyethylene Terephthalate Glycol):
light sources. SLA printing is known for its high level of detail and surface finish. Here are
 Properties: PETG combines the some common SLA 3D printing materials, along with their
ease of printing of PLA with some properties and applications:
of the mechanical properties of
1. Standard Resins:
ABS. It has good layer adhesion, is
impact-resistant, and offers  Properties: Standard SLA resins are known for
better temperature resistance their high level of detail, smooth surface finish,
than PLA. and a range of available colors. They are
relatively rigid and have good dimensional
stability.
  Applications: Standard resins are used for a wide range of applications, including SLS 3D Printing materials:
prototyping, jewelry, dental models, figurines, and small mechanical parts.
Selective Laser Sintering (SLS) is a powder-based 3D printing technology that uses a high-
2. Flexible Resins: powered laser to selectively fuse powdered materials layer by layer. Here are some
common materials used in SLS 3D printing, along with their properties and applications:
 Properties: Flexible SLA resins offer rubber-like
properties, including flexibility and elasticity. They
are designed for applications where parts need to
bend or stretch.

 Applications: Flexible resins are used for producing

gaskets, seals, shoe insoles, and prototypes of
products with soft-touch features.

3. Tough Resins:

 Properties: Tough SLA resins are

1. Nylon (PA - Polyamide):
engineered for impact resistance and
durability. They have high tensile  Properties: Nylon is a versatile material with good mechanical properties,
strength and can withstand rough including strength, flexibility, and durability. It offers excellent chemical resistance
handling. and can be reinforced with additives for enhanced properties.

 Applications: Tough resins are used for
functional prototypes, snap-fit components, and parts subjected to mechanical
stress.
4. Biocompatible Resins:
 Properties: Biocompatible SLA resins are
formulated to meet medical and dental industry
standards for biocompatibility. They are suitable
for creating dental models, surgical guides, and
custom medical devices.
 Applications: Used in the dental and medical fields
for applications requiring biocompatible materials.
5. Clear Resins:
 Properties: Clear SLA resins produce transparent
parts with optical clarity. They are often used for
creating lenses, light pipes, and clear prototypes.
 Applications: Nylon is used for functional prototypes, complex parts, end-use
products, automotive components, and consumer goods.
2. TPE (Thermoplastic Elastomer):
 Properties: TPE is a flexible and rubber-like material with good elasticity and shock
absorption. It is used for producing parts requiring a soft touch and impact
resistance.
 Applications: TPE is used for creating gaskets, seals, footwear components, and
ergonomic grips.
3. TPU (Thermoplastic Polyurethane):
 Properties: Similar to TPE, TPU is a flexible material with properties ranging from
soft to semi-rigid. It has good chemical resistance and durability.
 Applications: TPU is used for producing flexible hinges, gaskets, seals, and
functional prototypes.
4. PEEK (Polyether Ether Ketone):

 Applications: Clear resins are used for  Properties: PEEK is a high-performance engineering plastic with exceptional
applications where transparency and optical mechanical, thermal, and chemical resistance properties. It is suitable for
properties are critical, such as optics and demanding applications.
consumer electronics.
  Applications: PEEK is used in aerospace, medical implants, automotive, and other
industries for producing parts that require high strength, temperature resistance,
and biocompatibility.
5. Metal Powders (e.g., Stainless Steel, Titanium, Aluminum):
1. Sandstone (Gypsum):
 Properties: Sandstone is a brittle material that can produce detailed, full-color
models. It's not particularly strong but is suitable for decorative and architectural
applications.

 Properties: Metal SLS materials offer high strength, good thermal conductivity,  Applications: Used for architectural models, figurines, and artistic sculptures.
and the ability to produce complex geometries. Different metals have varying
2. Metal Powders (Stainless Steel, Bronze, Inconel, etc.):
properties.
 Properties: Metal powders used in Binder Jetting can offer high strength, excellent
 Applications: Metal SLS is used for producing functional prototypes, tooling,
thermal conductivity, and resistance to corrosion. The specific properties depend
aerospace components, medical implants, and customized parts for industrial
on the metal used.
applications.
 Applications: Commonly used for producing metal parts for aerospace,
6. Ceramic Powders (e.g., Alumina, Zirconia):
automotive, and industrial applications.
 Properties: Ceramic SLS materials offer high heat resistance, excellent electrical
3. Ceramic Powders (Alumina, Zirconia, etc.):
insulation, and chemical stability. They can have varying levels of hardness.
 Properties: Ceramic materials are known for their high-temperature resistance,
 Applications: Ceramic SLS is used for creating specialized components in
electrical insulation, and hardness. They can have various properties depending on
electronics, aerospace, medical, and other industries where high-temperature
the specific ceramic used.
stability is required.
 Applications: Used for manufacturing ceramic components such as insulators,
7. Composite Materials (e.g., Carbon-Filled Nylon):
dental crowns, and intricate, custom-designed ceramic parts.
 Properties: Composite SLS materials combine polymers with additives like carbon
4. Plastic Powders (Nylon, Polyamide, etc.):
fiber for enhanced mechanical properties, including strength and stiffness.
 Properties: Plastic powders in Binder Jetting can offer a range of properties,
 Applications: Used for producing lightweight but strong parts in aerospace,
including flexibility, durability, and impact resistance, depending on the material.
automotive, and sporting equipment industries.
 Applications: Used for producing prototypes, intricate parts, and objects that
require specific plastic properties.
Binder Jetting 3D Printing materials:
5. Sand and Ceramic Composite Materials:
Binder Jetting is a 3D printing technology that uses a powder bed and a binder material to
 Properties: These materials combine sand or ceramic powders with a binder to
create objects layer by layer. This process is often used for producing prototypes, intricate
create objects that are more durable than pure sandstone or ceramic prints.
parts, and objects with a range of materials. Here are some common materials used in
Binder Jetting 3D printing:  Applications: Used in applications where a balance of strength and detail is
required, such as in custom sand casting molds for metal parts.

6. Glass Powder:

 Properties: Glass powder in Binder Jetting can create transparent or translucent

objects with high optical clarity.

 Applications: Used for producing glass art, decorative objects, and prototypes
requiring optical properties.
 7. Food Materials:
 Properties: Binder Jetting can be adapted to print food materials like chocolate,
sugar, and other edible substances.
 Applications: Used in the culinary industry for creating custom-shaped chocolates,
cake decorations, and food prototypes.
Material Jetting 3D Printing materials:
Material Jetting is a 3D printing technology that deposits droplets of photopolymer
materials or wax-like materials layer by layer to create objects. It's known for its ability to
produce high-resolution and highly detailed parts. Here are some common materials used in
Material Jetting 3D printing:
1. Photopolymers:
 Properties: Photopolymers are liquid materials that solidify when exposed to UV
light. They offer a wide range of properties, including flexibility, rigidity,
transparency, and various colors.
 Applications: Material Jetting with photopolymers is often used for creating
detailed prototypes, dental models, medical devices, and products requiring
intricate geometries and smooth surface finishes.
2. Wax-like Materials:
 Properties: Wax-like materials are often used in investment casting processes.
They can be melted away, leaving behind a void that can be filled with molten
metal.
 Applications: Wax-like materials in Material Jetting are commonly used for jewelry
making, dental crowns, and parts that will undergo investment casting.
3. Support Materials:
 Properties: Material Jetting often employs separate support materials that can be
easily removed after printing. These support materials are designed to work with
the main printing material.
 Applications: Support materials are essential for creating complex and
overhanging geometries and can be used in a variety of applications, especially in
cases where intricate, high-detail parts are needed.
4. Multi-Material Printing:
 Properties: Some Material Jetting systems allow for the simultaneous use of
multiple materials in a single print job. This enables the creation of objects with
varying properties and colors within a single part.
 Applications: Multi-material printing is used for producing complex prototypes,
medical models, and products requiring both rigid and flexible components.
5. Full-Color Printing:
 Properties: Material Jetting technology can also incorporate full-color capabilities,
allowing for the production of parts with detailed, full-color textures and graphics.
 Applications: Full-color Material Jetting is used in industries like architecture,
entertainment, and consumer products for creating visually appealing models and
prototypes.
Direct Energy deposition 3D printing materials:
Direct Energy Deposition (DED) is an additive manufacturing process that uses a high-energy
heat source, typically a laser or an electron beam, to melt and fuse material feedstock onto
a substrate. DED is known for its versatility and is often used in repair, cladding, and the
production of large and complex parts. The choice of materials in DED can be extensive and
includes various metals, alloys, ceramics, and even some polymers. Here are some common
materials used in DED 3D printing:

1. Metal Powders:
 Properties: Metal powders are commonly used in DED processes to build up metal
parts layer by layer. Various metals and alloys can be used, including stainless
steel, titanium, aluminum, Inconel, and more.
 Applications: DED with metal powders is used in industries such as aerospace,
automotive, and oil and gas for creating large and complex metal parts, repairing
components, and adding wear-resistant coatings.
2. Ceramic Powders:
 Properties: Ceramic powders are used in DED to create parts with excellent
thermal and electrical insulating properties, as well as high-temperature
resistance. Examples include alumina and zirconia.
 Applications: Ceramic DED is used in applications like manufacturing ceramic
components for electronic devices, aerospace, and advanced ceramics.
3. Metal Wire:
 Properties: Metal wire is fed into the DED system and melted onto the substrate.
This process can be more cost-effective than using metal powders.
 Applications: Metal wire DED is used in industries requiring large metal parts, such
as shipbuilding and construction.
4. Ceramic Wire:
 Properties: Similar to metal wire, ceramic wire can be used in DED to produce
ceramic components with specific properties.
 Applications: Ceramic wire DED is used in the production of ceramic parts for
industrial and specialized applications.
5. Polymer Powders:
 Properties: Some DED systems are capable of using polymer powders, enabling
the creation of parts with different thermal and mechanical properties compared
to metals and ceramics.
 Applications: Polymer DED is used for creating lightweight parts, tooling, and
prototypes in industries like aerospace and automotive.
6. Hybrid Materials:
 Properties: In some cases, hybrid DED systems combine different materials, such
as metal and polymer, to create parts with unique properties.
 Applications: Hybrid DED can be used in applications that require a combination of
materials, such as lightweight structures with metal reinforcement.
1.3 Polymers, Metals, Non-Metals, Ceramics.
1. Polymers:
 Definition: Polymers are large molecules made up of repeating subunits. They are
characterized by their flexibility, lightweight nature, and diverse properties.
 Properties: Polymers used in 3D printing can vary widely in terms of flexibility,
strength, heat resistance, and other properties.
 Applications: Polymers are commonly used in 3D printing for producing prototypes,
consumer goods, medical devices, and more.
Examples of polymer 3D printing materials:
a) PLA (Polylactic Acid): Biodegradable, easy to print, used for prototyping.
b) ABS (Acrylonitrile Butadiene Styrene): Durable, impact-resistant, used for
functional parts.
c) PETG (Polyethylene Terephthalate Glycol): Combines the best of PLA and ABS
properties.
d) TPU (Thermoplastic Polyurethane): Flexible and elastic, used for soft parts.
e) Nylon: Strong, durable, used for functional and mechanical parts.
2. Metals: Examples of ceramic 3D printing materials:

 Definition: Metals are solid materials with high electrical and thermal conductivity, a) Alumina: High mechanical strength and electrical insulating properties.
often malleable and ductile.
b) Zirconia: High toughness and resistance to cracking.
 Properties: Metal 3D printing materials offer high strength, excellent thermal and
c) Silicon Carbide: Extremely high thermal conductivity and hardness.
electrical conductivity, and a range of other properties depending on the alloy.

 Applications: Metal 3D printing is used in aerospace, automotive, medical implants,

tooling, and more. 1.4 Polymers and their properties.

Examples of metal 3D printing materials: 1. PLA (Polylactic Acid):

a) Stainless Steel: Corrosion-resistant, strong, used for industrial parts.  Properties:

b) Titanium: High strength-to-weight ratio, biocompatible, used in aerospace and a) Biodegradable and environmentally friendly.
medical.
b) Easy to print, making it ideal for beginners.
c) Aluminum: Lightweight, good thermal conductivity, used in automotive and
c) Relatively low melting point, around 180-220°C.
aerospace.
d) Generally rigid and somewhat brittle.
3. Non-Metals:
e) Available in a wide range of colors and formulations.
 Definition: Non-metals encompass a wide range of materials that do not exhibit
metallic properties.  Applications:

 Properties: Non-metal 3D printing materials can include composites, ceramics, and a) Prototyping and hobbyist projects.
other materials with unique properties.
b) Decorative items and figurines.
 Applications: Non-metal materials are used in specialized applications where metal
c) Educational purposes.
properties are not required.
d) Packaging materials.
Examples of non-metal 3D printing materials:
2. ABS (Acrylonitrile Butadiene Styrene):
a) Carbon Fiber Reinforced Polymers: Lightweight and strong, used in aerospace and
sports equipment.  Properties:

b) Glass-Filled Nylon: Enhanced strength, used for engineering parts. a) Tough and impact-resistant.

c) Wood and Metal Composites: Used for aesthetic and artistic applications. b) Higher melting point, typically around 210-240°C.

4. Ceramics: c) Can be more challenging to print due to warping and fumes.

 Definition: Ceramics are inorganic, non-metallic materials that are typically brittle d) Excellent layer adhesion.
and have high heat resistance.  Applications:
 Properties: Ceramic 3D printing materials can have excellent thermal and electrical a) Functional parts in automotive and consumer electronics.
insulating properties, as well as high-temperature resistance.
b) Enclosures and casings.
 Applications: Ceramic 3D printing is used in aerospace, electronics, and applications
requiring high-temperature resistance and precision. c) Durable prototypes.
 d) LEGO bricks are made from ABS. Powder Preparation:

3. PETG (Polyethylene Terephthalate Glycol): 1. Particle Size Distribution: The powder particles should have a consistent size
distribution to ensure uniform packing and sintering during the printing process.
 Properties:
2. Powder Shape: Spherical or near-spherical particles are preferred as they allow for
a) Combines the ease of printing of PLA with some properties of ABS.
better flowability and packing density, reducing the chances of defects.
b) Good layer adhesion.
3. Surface Characteristics: The powder surface should be free of contaminants,
c) Moderate flexibility and impact resistance. oxidation, or impurities that could affect the sintering process or mechanical
properties of the final part.
d) Melting point around 220-260°C.
4. Flowability: Good flow properties are essential for uniform powder distribution in
 Applications:
the build chamber and proper layer deposition.
a) Functional parts requiring strength and durability.
5. Drying and Debinding: Some powders might need to undergo drying or debinding
b) Transparent or translucent items. processes to remove moisture or any organic binders, respectively.
c) Food-safe containers. Desired Properties of 3D Printing Powders:
d) Mechanical components. 1. Sinterability: The powder should sinter well under the energy source (laser or
electron beam) used in the 3D printing process, leading to strong bonding between
4. TPU (Thermoplastic Polyurethane):
particles.
 Properties:
2. Melting Point: The powder's melting point or sintering temperature should be
a) Highly flexible and elastic. appropriate for the specific 3D printing process without causing excessive thermal
b) Good resistance to abrasion and impact. degradation.

c) Melting point around 200-230°C. 3. Thermal Conductivity: Powders with good thermal conductivity are essential for
efficient energy absorption during the sintering process.
d) Available in various hardness levels.
4. Chemical Composition: The chemical composition of the powder must match the
 Applications: desired material properties, allowing for the production of parts with the required
a) Phone cases and protective gear. mechanical, thermal, and chemical characteristics.

b) Gaskets and seals. 5. Density: Higher powder density leads to better packing and improved mechanical
properties in the final part.
c) Flexible and stretchable prototypes.
6. Powder Purity: The powder should be free from impurities that could weaken the
d) Shoe soles and sportswear material's properties or introduce defects in the printed part.
1.5 Powder Preparation and their desired properties. 7. Particle Adhesion: Powder particles should have enough adhesion to each other to
Powder preparation is a crucial step in powder-based 3D printing processes, such as maintain their shape during handling, transport, and printing.
Selective Laser Sintering (SLS) and Electron Beam Melting (EBM). The quality and properties 8. Reusability: Some powder-based processes allow for the recycling of unused or
of the powder material play a significant role in the final printed part's characteristics. Here excess powder, so powders should maintain their properties through multiple cycles.
are some key aspects of powder preparation and the desired properties of 3D printing
powders: 9. Size and Shape Control: Consistent particle size and shape contribute to uniform
packing and layer quality during printing.
 10. Powder Handling: Ease of handling and processing during loading, spreading, and 6. Electrical Properties: Understand electrical conductivity, dielectric strength, and
recycling is important for efficient operation. other relevant electrical properties.

7. Other Properties: Evaluate properties like hardness, impact strength, UV resistance,

and flame retardancy if applicable.
1.6 Choosing the Right 3D Printing Material on the basis of Performance Requirements
and Material Properties. Step 3: Compare Materials:

Choosing the right 3D printing material based on performance requirements and material
properties involves a systematic approach to ensure the desired outcomes of your project.
Here's a comprehensive guide:
Step 1: Define Performance Requirements:
1. Material Databases: Utilize online material databases and resources provided by
manufacturers to compare properties side by side.
2. Material Compatibility: Ensure the selected material is compatible with your 3D
printer and its specifications.

1. Mechanical Properties: Determine the required strength, stiffness, and impact Step 4: Evaluate Trade-offs:
resistance for your part. Consider factors like load-bearing capacity and potential
1. Performance vs. Cost: Consider the balance between the desired performance and
mechanical stress.
the cost of the material.
2. Thermal Properties: Identify the temperature range your part will experience.
2. Ease of Printing: Evaluate how well the material works with your 3D printer,
Consider factors like heat resistance, thermal expansion, and conductivity.
including considerations like bed adhesion and nozzle temperature.
3. Chemical Compatibility: Understand the chemicals or substances your part will
3. Availability: Check the availability of the chosen material in your region and its lead
come into contact with and choose a material that is chemically resistant.
times.
4. Electrical Properties: Determine if your part needs to conduct electricity, insulate, or
Step 5: Test and Validate:
have specific electrical characteristics.
1. Prototyping: Create prototypes using the shortlisted materials to test their actual
5. Durability: Evaluate whether your part needs to withstand repetitive stress, fatigue,
performance under relevant conditions.
or wear over time.
2. Functional Testing: Subject prototypes to real-world conditions to validate their
6. Aesthetic Requirements: Consider factors such as color, surface finish, transparency,
performance against your defined requirements.
and texture.
3. Iterate if Necessary: If the initial material choice doesn't meet expectations, iterate
Step 2: Research Material Properties:
the process with new options.
1. Material Categories: Understand the properties and limitations of polymers, metals,
ceramics, and composites.

2. Material Datasheets: Study material datasheets provided by manufacturers to grasp

the specific properties of each material option.

3. Mechanical Properties: Compare tensile strength, flexural strength, Young's

modulus, and other mechanical data relevant to your requirements.

4. Thermal Properties: Compare heat deflection temperature, thermal conductivity,

and coefficient of thermal expansion.

5. Chemical Resistance: Check the material's resistance to chemicals, solvents, and

environmental conditions.
vivek