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Design Essentials for 3D Printing

for 3D Printing

DESIGN ESSENTIALS



TABLE OF CONTENTS3 Rapid Prototyping with Stereolithography

6 3D Printing Fully Functional Parts with Selective Laser Sintering

9 Redefining Part Design with Metal 3D Printing

12 How 3D Printing Materials Measure Up

Industrial 3D printing opens up many new design possibilities, but it’s important to keep a few fundamental principles in mind when designing for additive manufacturing processes. Most of these are fairly obvious like feature resolution, surface finish, and material selection, but there’s more to 3D printing success than selecting the right material and process. If you will eventually need increased part quantities through more traditional processes like injection molding, you should considering the part’s moldability even when designing early prototypes. Understanding the fundamental principles for 3D printing will help you get the most out the versatile technology—whether you're iterating part design through rapid prototyping or creating end-use production parts.

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RAPID PROTOTYPING WITH STEREOLITHOGRAPHYStereolithography, or SL, emerged in the mid-1980s and established itself as a staple of additive manufacturing (now known as 3D printing) over the next decade. Since that time, SL’s ability to quickly and accurately create complex prototypes has helped transform the design world like never before.

As with other 3D printing processes like selective laser sintering (SLS) and direct metal laser sintering (DMLS), SL relies on lasers to do the heavy lifting. Parts are built by curing paper-thin layers of liquid thermoset resin, using an ultraviolet (UV) laser that draws on the surface of a resin turning it from a liquid into a solid layer. As each layer is completed, fresh, uncured resin is swept over the preceding layer and the process repeated until the part is finished. A post-build process is required on SL parts, which undergo a UV-curing cycle to fully solidify the outer surface of the part and any additional surface finish requirements. Stereolithography uses a UV laser to cure thousands of individual layers into a final part.



Thermoplastic MimicUnlike older generations of SL, today’s machines offer a range of thermoplastic-mimic materials to choose from, with several flavors to mimic polypropylene, ABS, and glass-filled polycarbonate available. Proto Labs offers many variations of these materials:

• Polypropylene: A flexible, durable resin that mimics a stiff polypropylene. It can withstand harsh mechanical treatment and is great for fine details—sharp corners, thin walls, small holes, etc.

• Polypropylene/ABS blend: Strong, white plastic similar to a CNC-machined polypropylene/ABS blend. It works well for snap fits, assemblies, and demanding applications.

• ABS: Variations of ABS mimics include a clear, low-viscosity resin that can be finished clear; an opaque black plastic that blocks nearly all visible light, even in thin sections; a clear, colorless, water-resistant plastic good for lenses and flow-visualization models; a green micro-resolution resin that enables production of parts with extremely fine features and tight tolerances.

• Polycarbonate: A ceramic-filled PC material that provides strength, stiffness, and temperature resistance, but can be brittle.

• SLArmor: A nickel-plated material that gives SL-generated parts much of the strength and toughness associated with die cast aluminum.

Please note the term “thermoplastic mimic.” This is an important distinction in that the mechanical properties of SL materials only mimic those of their molded counterpart. If you need to pound on your prototype with a sledgehammer, or leave it in the sun for a few months, be aware that SL parts do not provide the same strength and durability as parts that are sintered, cast, machined, or molded. This makes SL the logical choice for prototype parts where validation of form and fit—but not necessarily function—is the most important factor. Customer service engineers at Proto Labs can help guide you during material and manufacturing process selection if help is needed.

A Fine ResolutionDespite differences in material properties, SL is the clear winner over SLS in terms of part accuracy and surface finish. Normal, high and micro resolutions are available, providing layer thicknesses ranging from 0.004 to 0.001 in. and part features as small as 0.002 in. This means very fine details and cosmetic surfaces are possible, with minimal “stair stepping” compared to printed parts built by processes like fused deposition modeling (FDM).

SL also has the edge in part size—need a prototype of a new luggage casing, or a lawnmower shell? There’s a good chance SL can accommodate. Proto Labs current max build size is 29 in. by 25 in. by 21 in. (736mm by 635mm by 533mm).

SL is also an excellent choice for prototyping microfluidic devices. Our microfluidic fabrication process allows engineers to accurately test parts that will later be injection molded, avoiding the hassles and high cost of photolithography. If you’re designing a protein sensor, micro-pump or lab on a chip, for example, SL prototyping might be just the ticket.

Final SL parts have support structures built in that are easily removed during post-processing. Supports help prevent part features from distorting during a build.



Other ConsiderationsStay away from extremely small holes as well, since the relatively high viscosity of the photo-curable resin used with SL can pose challenges during the post-build process. If you’re inventing a newfangled angel hair pasta strainer, one with holes smaller than 0.005 in., SL is probably not the best choice for a prototype. Thin walls should be monitored as well. The lid for a hi-tech sandwich container, for example, should have walls no less than 0.030 to 0.040 in. thick.

Bear in mind that we may create temporary structures to support your part during the build process, but these are removed prior to delivery and typically little evidence of their existence is found. We may also choose to orient the workpiece to facilitate a better build, in which case the cosmetic appearance of some surfaces can be affected—if certain cosmetic features on your part require an elevated level of surface finish, please indicate those surfaces when submitting your design.

Finishing MovesSpeaking of smooth surfaces, Proto Labs offers plenty of options for finishing SL parts. Most of our customers opt for light sanding to remove the aforementioned nibs left from supports, followed by a fine bead blast. Parts can be shipped “as is” and will show some evidence of the support structures. There are also several coating choices available—aside from the nickel SLArmor, painting (with color matching and masking services available), clear coat, texturing, and even custom decals are also possible.

As for preferred 3D CAD file formats for SL, Proto Labs accepts STL files. Most commercial CAD systems can generate STL files, the native format of any SL machine, but if yours doesn’t have this capability, our advice is to submit a neutral file format—such as an IGES or STEP file. But steer clear of the freeware STL generators littering the internet. Some tend to create incomplete STL files, meaning additional rework time and delayed production.

SL plays an important step in the design process. It bridges the gap between digital models and machined or injection-molded parts, giving people the ability to touch and feel prototype designs within days. Costly mistakes can be avoided, development costs reduced, and better products built in the long run.

Stereolithography machines cure liquid thermoset resins with an ultraviolet laser to produce high-resolution parts.



3D PRINTING FULLY FUNCTIONAL PARTS WITH SELECTIVE LASER SINTERING Sintering is the process of applying heat and/or pressure to fuse bits of metal, ceramic, and other materials into a solid mass. It’s nothing new. Nature has been fusing sedimentary minerals into slate and quartzite for eons, and humans began using similar methods to make bricks and porcelain millennia ago. Today, sintering is used to produce everything from gears and connecting rods to sprockets and bearings. It’s also used to 3D-print parts.

Selective laser sintering (SLS) is a close cousin to direct metal laser sintering (DMLS), but builds parts made of plastic rather than metal. SLS uses a computer-controlled CO2 laser versus an ND: YAG fiber laser for DMLS, but both “draw” slices of a CAD model in a bed of material, fusing micron-sized particles of material one layer at a time.

SLS needs none of the support structures typical with DMLS, however, and unlike stereolithography (SL)—the third laser-based 3D printing process available at Proto Labs—SLS creates fully functional parts using engineering-grade nylon, and is essentially the only 3D

printing technology able to create living hinges and snap-fit assemblies. (These features can be produced with SL, however, they will be much more fragile and not have the life expectancy of those produced with SLS. This makes it an excellent way to prototype injection-molded products, and can even be used as a low-volume alternative to molding in some cases.

Rooted in Nylon As with any 3D printing process, it’s important to understand the many design considerations applicable to SLS. One of these is the material. Despite their wide-ranging uses, all SLS parts are currently limited to nylon materials—the same thermoplastics used in fasteners, flak jackets, frying pans and thousands of other everyday items. Proto Labs offers four grades of these versatile polymers:

• PA 850 Black: Similar to an unfilled Nylon 11, this tough bioplastic is an excellent choice for parts requiring a living hinge—the lid on a pill container, for example—and offers one of the highest elongation break thresholds in the nylon family. It’s black in color, produces a smooth surface finish, and good part detail. And due to its superb chemical resistance and low water absorption, is ideal for products such as fuel lines and catheters, tennis shoes, and electrical connectors.

• PA 650 White: Similar to unfilled Nylon 12, PA 650 is both stiff and tough, and is used extensively in air ducts, sporting goods, and similar products. It presents a clean, white finish, but with a slightly rougher surface texture than other nylons. It offers high impact and temperature resistance, is very durable and remains stable under a range of environmental conditions. Nylon 12 also has a low coefficient of friction, making it suitable for many types of gears and bearings.

• PA 620-MF: A variant of Nylon 12, this material contains 25-percent mineral fiber, and is used for products requiring high structural strength and load-bearing properties. Like most nylons, it offers excellent stiffness at elevated temperatures, which is one reason why MF-filled nylon is a favorite among the aerospace and motorsports industries, and any applicationneeding an material that is strong and durable. It also has directional mechanical properties—the fibers will align in the X direction making it the strongest along that plane.



• PA 615-GS: This 50-percent glass-filled flavor of Nylon 12 is known for dimensional stability and resistance to high temperatures. It’s especially good for accurate, detailed parts with complex geometries, and outperforms unfilled nylon in demanding applications. However, the glass fill can be abrasive to mating surfaces, something that should be considered when designing parts with this rugged material. Both 615 and 620-MF will be much less flexible and 615-GS will be much heavier due to the glass content. It’s also important to note that 620-MF has a much better strength-to-weight ratio than 615-GS.

Managing the BuildThese four types of nylon materials cover many different applications. Despite this, roughly 95-percent of the SLS material consumed at Proto Labs is PA 850 (Nylon 11) or PA 650 (Nylon 12), although the mineral- and glass-filled variants are gaining momentum. There’s far more to effective part design than material selection, however, and controlling the in-build curl and post-build warping common with 3D printing is paramount to good part quality.

Much of this control falls to Proto Labs. To keep parts straight and true, our technicians will often tip parts slightly in the build chamber—if you’re designing a case for a handheld video game, for example, a compound incline of 10 to 15 degrees in the X and Y axes during the build is probably all that’s needed to keep the walls square and the box lid fitting smoothly.

SLS uses a computer-controlled CO2 laser, which draws slices of a CAD model in a bed of material, fusing micron-sized particles of material one layer at a time.



It’s important to point out that some “stair stepping” may occur as a result of this technique, so it’s important to identify cosmetic surfaces when submitting your design to Proto Labs for quoting and analysis.

For especially challenging parts, ribs can be used to strengthen large, flat surfaces—if your handheld game design requires a thin lid, a honeycomb, or checkerboard pattern on the inside surface will not only strengthen the lid, but also reduce material cost and potential warping.

It’s Never Too Early to Improve MoldabilityMany of the rules applied in injection molding also apply to SLS, making it a solid choice for parts that will eventually be molded.

The use of hole bosses and support struts, and avoiding thick cross-sections are good practices for either manufacturing process. Additional design considerations include:

• adding corner radii where walls meet to reduce stress

• uniform wall thickness—between 0.060 in. and 0.150 in. is recommended to reduce in-build curl and potential for warping

• integrating ribs to reduce warping

Where injection-molded parts can contain overmolded metal bushings or threaded inserts, SLS parts achieve comparable functionality via heat-stake inserts—in our handheld game example, threaded inserts can be heat-staked as a secondary process at each corner of the housing for strong assembly purposes.

Look and FeelThe surface finish produced by SLS is a bit rougher than other 3D printing technologies—anywhere from 100-250 RMS—but is still works reasonably well for most functional prototypes. Proto Labs also bead blasts the majority of customers’ parts to remove loose powder and create a smooth matte finish. Very fine text is another consideration—since the minimum feature size with SLS is 0.030 in., very small fonts tend to get jammed with powder, making letters and numbers less legible. Moving to inset text provides better results, but is still limited to features no smaller than approximately 0.020 in. Lastly, SLS is slightly less accurate than competing laser sintering processes—where DMLS has expected tolerances of ±0.003 in. plus an additional 0.001 in./in. on metal parts, ±0.003 in. plus ±0.001 in./in. is typically achievable with SLS on well-designed parts.

The upside here is that SLS has a build frame of 19 in. by 19 in. by 22 in. (482mm by 482mm by 558mm), far larger than its metal-making sidekick. And because there are no support structures involved, the entire powder bed can be utilized, making it easy to nest multiple parts into a single build. This makes SLS a solid alternative to machined plastic, a logical stepping-stone to injection molding, and an excellent way to produce functional nylon parts in higher volumes than is usually associated with 3D printing.

Implementing radiused corners reduces stress, warping, and makes for an easy transition to injection molding.



REDEFINING PART DESIGN WITH METAL 3D PRINTINGIt’s one of the basic rules of manufacturing: As part complexity increases, so do machining and assembly costs. But what if there were a different way to produce metal parts, one with fewer limitations than traditional milling, turning, and grinding processes, and able to build complex parts in less time and with little human intervention?

Enter the industrial 3D printing process of direct metal laser sintering. Through additive manufacturing technology, DMLS produces fully functional metal prototypes and end-use parts, simplifies assembly by reducing component counts, and offers virtually unlimited part complexity with no additional cost.

DMLS works by slicing part CAD models into paper thin layers and then drawing them with a laser in a bed of metal powder to form a final part.



Gaining SupportDMLS works by slicing part models into paper thin layers and then “drawing” them with a laser in a bed of powdered aluminum, Inconel, titanium, stainless steel, cobalt chrome, and other metals. Starting from the bottom layer and working up, each metal particle is melted and fused to its neighbors, one layer at a time until the part is complete. The result is a fully dense metal product with mechanical strength and fatigue characteristics little different than—and in some cases exceeding—one machined from comparable wrought, forged, or cast material, but produced with minimal tooling costs, significantly reduced setup times, and little waste.

If you’re ready to climb aboard the DMLS express, there are a few things you should know first. Although the technology produces fully dense parts from high strength, corrosion resistant metals, certain part features are prone to warping and curl if not supported properly during the build process. The design of build supports isn’t something you as a product designer or engineer necessarily need to be concerned with, but you do need to know that some shapes are exceptionally difficult to build, and by altering your part design somewhat, costs may come down while product quality goes up.

Learning the ABCs Let’s take the entire alphabet for example. One of the cool things about DMLS is you can print a number of different components in the same build, provided they fit within the machine’s build chamber, which in Proto Labs’ case, is a volume measuring roughly 10 in. by 10 in. by 10 in. (250mm3).

Let’s start with the letter A. Unless the horizontal crossbar is less than 0.080 in. across (2mm), vertical supports will be required beneath it to prevent warpage. Not a problem, but it’s going to cost a bit to grind or machine those supports away after the build. Same with a T—without supports beneath the

overhanging top section, it’s going to curl up like a goalpost. Letters B, D, P, and R are especially problematic because the supports will be left inside the part, where they’re most difficult to remove. Curved shapes like O and Q fare no differently, unless the letters are quite small, about the diameter of a soda straw. In fact, about the only letters that won’t need any form of support are X and Y, provided the arms are angled at least 45 degrees from the horizontal.

Orientation DayWait a minute—why not just lay the letters on their backs? “Eureka,” you say, and go home early. In this case, all of the letter’s walls are vertical, and the only support needed is a series of interconnected vertical braces between the bottom of each letter and the DMLS build plate, sort of like the scaffolding used to support workers during a building renovation. These are easy to remove once the build is complete, and avoids direct contact with large, flat part surfaces that can warp or damage the build plate. This approach also provides the best surface finish, since roughness increases as walls deviate from vertical in DMLS-printed parts, and is worst on angled down-facing surfaces.

Wall thickness is another consideration. Thin

In the "alphabet" example in this design tip, the letter A represents a part with a horizontal crossbar. Unless that crossbar is less than 0.080 in. across (2mm), vertical supports will be required beneath it to prevent warping, as this example shows.



walls below 0.040 in. (1mm) must maintain a wall height-to-thickness ratio of less than 40:1 or the structure may tumble. On the other end of the spectrum, very thick walls are wasteful and take a long time to build—better to hollow them out with a honeycomb or lattice structure, reducing material costs and processing time while preserving structural integrity.

Indeed, lattice structures are one of the best tricks up an additive magician’s sleeve. They’re virtually impossible to produce via conventional machining methods, but are fairly simple with DMLS. So too are treelike structures, gentle twisting seashell curves, and other organic shapes, all of which are cost-effective to produce with 3D printing—all that’s required is a little imagination and the right CAD software.

One final consideration is this: while Proto Labs encourages product designers and engineers to think outside the box, it’s important to keep an eye on the finish line. DMLS provides the opportunity to push the limits on prototype and low-volume part design, but it’s not yet viable for high-volume production because of economic factors. It’s therefore an excellent idea to explain the entire product life cycle to someone knowledgeable in all types of manufacturing, so you don’t inadvertently design your product only to find it’s not scalable beyond a few hundred pieces.

https://www.protolabs.com/cnc-machining/design-guidelines/threaded-holes



HOW 3D PRINTING MATERIALS MEASURE UP3D printing is different from all other manufacturing processes, so the material properties and characteristics of parts that it produces are different, even when using a nearly identical alloy or thermoplastic. In terms of material properties, it is not a matter of being better or worse; it is simply important to recognize that the results will be different.

Recognizing that there is a difference, the following information will aid in the characterization, and ultimately the selection, of materials from three widely used industrial 3D printing processes: direct metal laser sintering (DMLS), selective laser sintering (SLS) and stereolithography (SL).

Material AdvancementsThe materials used in 3D printing have been improving, as would be expected. These advancements have allowed the technology to move beyond models and prototypes to functional parts for testing, shop floor use and production.

And while the output of 3D printing is different from that of other manufacturing processes, it can offer a suitable alternative when seeking a direct replacement. Yet, its advantages increase when users experiment with the possibilities that it offers.

Direct Metal Laser SinteringDMLS uses pure metal powders to produce parts with properties that are generally accepted to be equal or better than those of wrought materials. Because there is rapid melting and solidification in a small, constantly moving spot, DMLS may yield differences in grain size and grain boundaries that impact mechanical performance. Research is ongoing to characterize the grain structures, which can change with the laser parameters, post-build heat treatment and hot isostatic pressing.

However, the results are not widely available. Ultimately, this difference will become an advantage when grain structure can be manipulated to offer varying mechanical properties in a part.

Of the three additive manufacturing processes discussed here, DMLS produces parts with material properties that approach an isotropic state. However, there will be some property variance when measured along different axes. For a visual comparison of DMLS material properties, see Chart 1 for tensile strength, Chart 2 for elongation and Chart 3 for hardness.

After an SLS part is built, the build technician removes the support structures manually.

DMLS support structures are typically removed with hand tools. In some cases additional machining is required.



TENSILE STRENGTH

0 50 100 150 200 250

DIRECT METAL LASER SINTERING

DMLSAluminum

Wrought MetalDie-cast AL

DMLSInconel 718

Wrought MetalIN718

DMLSSS 17-4

Wrought Metal17-4 Machined

DMLSCobalt Chrome

Wrought MetalF75 CoCr

DMLSTitanium

Wrought MetalTi 23

DMLSSS 316

Wrought Metal316 Machined

37.7 ksi

130 ksi

180 ksi

129 ksi

95 – 140 ksi

160 ksi

125 ksi

160 – 210 ksi

85 ksi

70 ksi

43.5 ksi

190 ksi

MATERIAL

KILOPOUNDS PER SQUARE INCH

Chart 1



ELONGATION

0% 20% 40% 60% 80% 100%


DMLSAluminum


DMLSInconel 718

Wrought MetalIN718

DMLSSS 17-4


DMLSCobalt Chrome


DMLSTitanium

Wrought MetalTi 23

DMLSSS 316


1%

20%

12%

10%

>8 – 20%

25%

10%

5 – 7%

56%

30%

2 – 5%

8%

MATERIAL

PERCENT

Chart 2



HARDNESS

40 60

0

80

20

100

40

120

60


DMLSAluminum


DMLSInconel 718

Wrought MetalIN718

DMLSSS 17-4


DMLSCobalt Chrome


DMLSTitanium

Wrought MetalTi 23

DMLSSS 316


25 HRC

35.5 HRC

39 HRC

40 – 47 HRC

25 – 35 HRC

47.2 HRB

76.5 – 101 HRB

40 – 50 HRB

81 HRB

36 HRC

35 – 45 HRC

36 HRC

MATERIAL

MATERIAL

ROCKWELL HARDNESS - HRC

ROCKWELL HARDNESS - HRB

Chart 3



Selective Laser SinteringSLS uses thermoplastic powders, predominantly polyamide (PA), to make functional parts that have greater toughness and higher impact strength than parts produced through SL, as well as high HDTs (351°F to 370°F). The tradeoffs are that SLS lacks the surface finish and fine feature details available with SL.

Generally, SLS PAs, when compared to the average values of their injection-molded counterparts, have similar HDT values but lower values for the mechanical properties. The exception is the fiber-filled DuraForm HST composite, which exceeds a mineral-filled PA 12 in all areas except tensile strength. In a few instances, SLS PAs report properties that document the degree of anisotropism. For a visual comparison of SLSmaterial properties, see Chart 4 for heat deflection, Chart 5 for elongation at break and Chart 6 for tensile strength.

ELONGATION AT BREAK

0% 20% 40% 60% 80% 100%

SELECTIVE LASER SINTERING

DuraForm HST

Molded Nylon (PA)40% Mineral PA

Molded Nylon (PA)33% Glass PA

Molded Nylon (PA)Unfilled PA

PA 615-GS

PA 850

PA 650

2.7 – 4.5%

1.6%

14 – 51%

24%

2 – 3%

2.5%

15 – 60%

MATERIAL

PERCENT

HEAT DEFLECTION

0° 100° 200° 300° 400° 500°

SELECTIVE LASER SINTERING

DuraForm HST




PA 615-GS

PA 850

PA 650

276° – 363°

273° – 350°

118° – 370°

186° – 350°

465° – 495°

410° – 476°

158° – 410°

MATERIAL

DEGREES° IN FAHRENHEIT

Charts 4 & 5



0 10 20 30 40 50

KILOPOUND PER SQUARE INCH

TENSILE STRENGTHSELECTIVE LASER SINTERING

DuraForm HST




PA 615-GS

PA 850

PA 650

4.5 – 7.35 ksi

4.5 ksi

6.1 – 6.95 ksi

6.96 ksi

20.0 – 29.0 ksi

12.62 ksi

5.51 – 16.5 ksi

MATERIAL

Chart 6



StereolithographySL uses photopolymers, thermoset resins cured with ultraviolet (UV) light. It offers the broadest material selection with a large range of tensile strengths, tensile and flexural moduli, and EBs. Note that the impact strengths and HDTs are generally much lower than those of common injection-molded plastics. The range of materials also offers options for color and opacity. Combined with good surface finish and high feature resolution, SL can produce parts that mimic injection molding in terms of performance and appearance.

The photopolymers are hygroscopic and UV sensitive, which may alter the dimensions and performance of the part over time. Exposure to moisture and UV light will alter the appearance, size and mechanical properties. For a visual comparison of SL material properties, see Chart 7 for heat deflection Chart 8 for elongation at break and Chart 9 for tensile strength.

HEAT DEFLECTION

0° 100° 200° 300° 400° 500°

STEREOLITHOGRAPHY

Accura 5530

Accura Xtreme White

SLArmor10% Metal Volume



Die-castAluminum

Somos 9120

PP (Molded)

Accura 60

Somos Nano Tool

PC (Molded)

RenShape 7820

MicroFine Green

Somos Watershed

ABS (Molded)

131° – 482°

118° – 131°

185° – 437°

250° – 280°

185° – 215°

108° – 117°

126° – 142°

124° – 203°

122° – 516°

122° – 516°

122° – 516°

122° – 138°

115° – 130°

125°

Greater than 500°

MATERIAL

DEGRESS° IN FAHRENHEIT

Chart 7

ABS METAL

MOLDED MATERIAL COMPARISON KEY

POLYCARBONATE POLYPROPYLENE



ELONGATION AT BREAK

0% 20% 40% 60% 80% 100%

STEREOLITHOGRAPHY

Accura 5530

Accura Xtreme White




Die-castAluminum

Somos 9120

PP (Molded)

Accura 60

Somos Nano Tool

PC (Molded)

RenShape 7820

MicroFine Green

Somos Watershed

ABS (Molded)

1.3 – 4.4%

5 – 13%

0.7 – 1.0%

100%

30%

7 – 20%

15 – 25%

100%

0.9%

1.04%

1%

6.1%

11 – 20%

8 – 18%

2 – 5%

MATERIAL

PERCENT

Chart 8

ABS METAL





TENSILE STRENGTH

0 10 20 30 40 50

STEREOLITHOGRAPHY

Accura 5530

Accura Xtreme White




Die-castAluminum

Somos 9120

PP (Molded)

Accura 60

Somos Nano Tool

PC (Molded)

RenShape 7820

MicroFine Green

Somos Watershed

ABS (Molded)

6.8 – 8.9 ksi

8.41 – 9.86 ksi

8.9 – 11.3 ksi

7.25 – 10.44 ksi

4.64 – 6.1 ksi

6.3 – 7.25 ksi

4.4 – 4.7 ksi

3.92 – 5.801 ksi

14.0 ksi

21.0 ksi

29.0 ksi

6.5 ksi

6.8 – 7.8 ksi

5.2 – 7.4 ksi

43.5 ksi

MATERIAL

KILOPOUND PER SQUARE INCH

Chart 9

ABS METAL





ConclusionSpanning 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. For additional information on selecting the right material refer to our decision trees below.

STRENGTH

LIGHTWEIGHT

TEMPERATURE RESISTANCE

CORROSION RESISTANCE

STRENGTH-TO-WEIGHT RATIO

ATTRIBUTES

METAL

Inconel 718Titanium Ti-6-4Stainless Steel 17-4 PH

AluminumTitanium Ti-6-4

Inconel 718Titanium Ti-6-4

AluminumCobalt Chrome

Stainless Steel 316LInconel 718Titanium Ti-6-4Stainless Steel 17-4 PH

DMLS

Decision Tree: DMLS Material



SLS

STRENGTH

TRANSPARENCY

WATER RESISTANCE

TEMPERATURERESISTANCE

HIGH RESOLUTION

DURABILITY

STIFFNESS

IMPACT RESISTANCE

COLOR

ATTRIBUTES

PLASTIC

Accura Xtreme White 200SLArmorDuraForm HST Composite

Accura 60Somos WaterShed XC 11122

Accura 5530Somos WaterShed XC 11122

Accura 60MicroFine GreenSomos 9120

Accura Xtreme White 200SLArmorALM PA 650PA 850 Black

Somos NanoToolSLArmorDuraForm HST CompositePA 615-GS

Accura Xtreme White 200PA 850 Black

RenShape 7820MicroFine GreenPA 850 Black

Accura 5530 Somos NanoToolDuraForm HST CompositePA 615-GS

SL

Decision Tree: SL and SLS Material

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