3D printing equipment builds three-dimensional products by layering material based on the design of three-dimensional models. This layer-by-layer stacking technology is also known as “additive manufacturing.”

3D printing integrates advanced technologies from digital modeling, electromechanical control, information technology, materials science, and chemistry.

technology, known as the core technology of the ‘Third Industrial Revolution’.

Compared to traditional manufacturing, 3D printing eliminates the need for molds, material removal, and complex forging, enabling structural optimization, material savings, and energy efficiency.

3D printing technology is ideal for new product development, rapid small-batch manufacturing, complex part production, mold design, and difficult-to-machine materials. It also aids in shape design checking, assembly inspection, and rapid reverse engineering. With increasing global attention, the 3D printing industry is set to become a promising sunrise sector.

At present, industries have applied 3D printing to product prototypes, mold manufacturing, art and creative products, jewelry production, and other fields. This technology replaces traditional fine machining processes, significantly enhancing production efficiency and precision. Additionally, fields such as bioengineering, medicine, construction, and clothing have introduced 3D printing technology, opening up broader opportunities for its development.

The United States, Europe, and Japan are leading the 21st-century manufacturing competition by investing heavily in rapid prototyping technology, driving the rapid development of 3D printing.

In national defense, the United States and Europe prioritize 3D printing technology, investing heavily in the development of additive manufacturing for metal parts, particularly titanium alloys and other high-value materials.

Material is an important fundamental of 3D printing but also the bottleneck of the current constraints on its development. Here is a brief overview of the current development of 3D printing materials and the existing challenges.

3D printing materials

3D printing materials are an important material basis for developing 3D printing technology. Materials development determines whether 3D printing can have a wider range of applications. At present, manufacturers primarily use engineering plastics, photosensitive resins, rubber materials, metal materials, and ceramic materials for 3D printing. Additionally, they have utilized colorful gypsum materials, artificial bone powder, cell biological raw materials, and even sugar and other food materials in the field of 3D printing.

These raw materials are specifically developed for 3D printing equipment, processes, and research, unlike ordinary plastics. gypsum, resin, etc., there is a difference: its material development determines whether 3D printing can have a wider range of applications. The shape of the material is generally powder, filament, laminated, liquid, etc. Powdered 3D printing materials, with particle sizes of 1-100μm, require high sphericity for good flow, depending on the equipment and conditions.

1. Engineering plastics

Engineering Plastics in 3D Printing

Engineering plastics are used extensively as industrial parts or shell materials due to their superior properties, such as:

• High strength
• Impact resistance
• Heat resistance
• Hardness
• Aging resistance

These materials are currently the most widely used class of 3D printing materials. Some of the common engineering plastics include:

• Acrylonitrile Butadiene Styrene (ABS)
• Polycarbonate (PC)
• Nylon materials

ABS (Acrylonitrile Butadiene Styrene) in 3D Printing

ABS is commonly used in the Fused Deposition Modeling (FDM) rapid prototyping process for thermoplastic engineering plastics. Its notable features include:

• High strength
• Good toughness
• Impact resistance

ABS has a deformation temperature above 90°C and can be processed through various methods such as drilling, tapping, painting, and electroplating. The material comes in a variety of colors including ivory, white, black, dark grey, red, blue, and rose red. It is widely used in:

• Automotive industry
• Home appliances
• Consumer electronics

Polycarbonate (PC) in 3D Printing

Polycarbonate (PC) is a true thermoplastic material with excellent engineering properties, including:

• High strength
• High-temperature resistance
• Impact resistance
• Bending resistance

PC materials are suitable for producing final parts and can be directly assembled. They are commonly used in:

• Transportation
• Home appliances
• Consumer electronics
• Aerospace
• Medical equipment

While PC materials come in a single color (white), their strength is approximately 60% higher than that of ABS, making them a preferred choice in industries that require high-performance materials.

Nylon with Fiberglass in 3D Printing

Nylon fiberglass is a white powder that enhances the mechanical properties of standard nylon. Key characteristics include:

• Enhanced tensile and bending strength
• Increased heat distortion temperature and modulus
• Reduced material shrinkage

However, it results in a rougher surface and slightly reduced impact strength. With a heat distortion temperature of 110°C, this material is commonly used in:

• Automotive industry
• Home appliances
• Consumer electronics

PC-ABS in 3D Printing

PC-ABS is a versatile thermoplastic that combines the toughness of ABS with the high strength and heat resistance of PC materials. This material is extensively used in industries like:

• Automotive
• Home appliances
• Telecommunications

Parts made from PC-ABS using FORTUS equipment exhibit around 60% greater strength than those made with traditional FDM systems. It is ideal for creating:

• Conceptual models
• Functional prototypes
• Manufacturing tools
• Final parts

Polycarbonate-ISO (PC-ISO) in 3D Printing

Polycarbonate-ISO (PC-ISO) is a hygienically certified thermoplastic material commonly used in the pharmaceutical and medical device industries. It is known for its high strength and suitability for applications such as:

• Surgical simulation
• Cranial repair
• Dentistry

Because of its properties, PC-ISO is also used in the food and pharmaceutical packaging industries. Like other polycarbonate materials, it can be used to create:

• Conceptual models
• Functional prototypes
• Manufacturing tools
• Final parts

Polysulfone (PSU) in 3D Printing

Polysulfone (PSU)-based materials are amber-colored thermoplastics with exceptional heat resistance. Key properties include:

• Heat deflection temperature of 189°C
• Strong resistance to heat and corrosion

PSU materials are widely used for final components in industries such as:

• Aerospace
• Transportation
• Healthcare

PSU-based materials provide stable performance, and when used with FORTUS equipment, they can achieve outstanding results in direct digital fabrication applications.

2. Photosensitive resins

Light-sensitive resins, also known as ultraviolet (UV) resins, combine polymer monomers and prepolymers with UV initiators (or photosensitizers). Ultraviolet light of a specific wavelength (250–300 nm) immediately triggers a polymerization reaction, completing the curing process.

Photosensitive resins are generally liquid and make high-strength, high-temperature-resistant, and waterproof materials. Currently, 3D printing of photosensitive materials is primarily researched by 3D Systems (USA) and Objet (Israel). common photosensitive resin Somos Next material, resin Somos 11122 material, Somos 19120 material, and epoxy resin.

Somos Next is a tough, white PC-like material with better precision and surface quality than nylon materials made by selective laser sintering (SLS).

Parts made from Somos Next offer the best rigidity and toughness while maintaining precision, accuracy, and aesthetic appeal for automotive, home appliance, and consumer electronics applications.

Somos 11122 material looks more like real transparent plastic. It offers excellent water resistance, dimensional stability, and engineering plastics-like properties, including ABS and PBT, making it suitable for automotive, medical, and electronic products.

Somos 19120, a pink casting material, directly replaces the wax film prototype for precision casting. This avoids mold development risk and reduces cycle time, with low ash retention and high precision.

Epoxy resin serves as a casting-friendly laser rapid prototyping resin. It leaves minimal ash content (<0.01% at 800 ℃) and works well with fused silica and alumina high-temperature shell systems. Free of heavy metals like antimony, it enables the manufacture of extremely precise rapid-casting molds.

3. Rubber-based materials

Rubber materials have a variety of levels of elastic material characteristics. These materials have high hardness, elongation, tear strength, and tensile strength, making them ideal for non-slip or soft surface applications. Industries use 3D printing to produce rubber products for consumer electronics, medical equipment, automotive interiors, tires, gaskets, and more.

4. Metal materials

3D Printing in Metal Manufacturing

In recent years, 3D printing technology has been gradually applied to the manufacture of actual products, with the 3D printing of metal materials seeing particularly rapid development. Countries such as those in Europe and the United States are heavily investing in the research and development of 3D printing technology, with a focus on metal parts and components for national defense applications.

Metal Powder Requirements for 3D Printing

The metal powder used in 3D printing must meet general requirements such as high purity and good sphericity. Specifically, the powder should have:

• High purity
• Good spherical shape
• Narrow particle size distribution
• Low oxygen content

Common Metal Powders for 3D Printing

Several metal alloys are commonly used for 3D printing:

• Titanium Alloys
• Cobalt-Chromium Alloys
• Stainless Steel
• Aluminum Alloys
• Precious Metals (e.g., gold, silver) for jewelry printing

Titanium Alloys in 3D Printing

Titanium is an important structural metal, and titanium alloys are used in high-performance applications due to their:

• High strength
• Excellent corrosion resistance
• Heat resistance

These alloys are commonly used in the production of aircraft engine compressor parts, rockets, missiles, and aircraft structural components.

Cobalt-Chromium Alloys in 3D Printing

Cobalt-chromium alloys are high-temperature alloys with superior corrosion resistance and mechanical properties. These materials are ideal for producing high-strength, high-temperature components. Using 3D printing technology, parts made from titanium and cobalt-chromium alloys exhibit:

• Very high strength
• Precise size
• Capabilities to produce parts as small as 1mm
• Mechanical properties superior to those produced through forging processes

Stainless Steel in 3D Printing

Stainless steel is highly resistant to various forms of corrosion, including from air, steam, water, and chemical agents like acids, alkalis, and salts. As a cost-effective material for 3D printing, stainless steel powder is often used in the manufacturing of larger components. The resulting stainless steel parts are durable, strong, and reliable, making them a common choice for a variety of industrial applications.

technology has been gradually applied to the manufacture of actual products, in which the 3D printing technology of metal materials is developing particularly rapidly; in the field of national defense, Europe and the United States developed countries attach great importance to the development of 3D printing technology, at the expense of investing huge sums of money to research, and 3D printing of metal parts and components has always been a key focus of research and application.

3D printing utilizes metal powders to meet requirements for high purity and good sphericity. Manufacturers ensure that these powders have high purity, good sphericity, a narrow particle size distribution, and low oxygen content.

3D printing uses metal powders like titanium alloys, cobalt-chromium alloys, stainless steel, aluminum alloys, and precious metals like gold and silver for jewelry.

 

5 . Ceramic Materials

Ceramic materials offer high strength, hardness, heat resistance, low density, chemical stability, and corrosion resistance, making them ideal for aerospace, automotive, and biological industries. They have a wide range of applications, but ceramic materials’ hard and brittle characteristics make them particularly difficult to process and form, especially complex ceramic parts that need to be formed through molds. Mold processing is costly, time-consuming, and struggles to meet the demand for continuous product updates.

Ceramic Materials in 3D Printing

Ceramic materials possess excellent characteristics such as:

• High strength
• High hardness
• High-temperature resistance
• Low density
• Good chemical stability
• Corrosion resistance

These qualities make them highly valuable in industries such as aerospace, automotive, and biological applications. However, ceramic materials have hard and brittle properties, which make them particularly difficult to process and form, especially when it comes to creating complex ceramic parts.

Challenges in Traditional Ceramic Manufacturing

The processing of ceramic materials, particularly for complex parts, often requires molding. This approach can be costly and time-consuming, with the following challenges:

• High mold processing costs
• Long development cycles
• Difficulty in meeting continuous product updates

As a result, traditional manufacturing methods struggle to keep pace with the growing demand for ceramic products with frequent updates.

Ceramic Powder for 3D Printing

In 3D printing, ceramic powder is mixed with a binder powder to form a printable material. The binder powder has a lower melting point, allowing for laser sintering to melt only the binder powder, which then binds the ceramic powder together. After the laser sintering process, the ceramic parts require additional post-processing in a temperature-controlled furnace at higher temperatures.

Effect of Ceramic and Binder Powder Ratio

The ratio of ceramic powder to binder powder plays a critical role in determining the performance of the printed ceramic parts. Key considerations include:

• Higher binder content:

  • Easier sintering
  • Greater shrinkage during post-processing, affecting dimensional accuracy

• Lower binder content:

  • Harder to sinter and mold
  • Better sintering quality when ceramic particles are smaller and have a more spherical shape

The closer the ceramic particle surface is to a spherical shape, the better the sintering properties, leading to improved part quality.

Challenges in Ceramic Sintering

During laser direct rapid sintering, the ceramic powder experiences high liquid phase surface tension, which leads to rapid solidification and significant thermal stress. This stress can cause the formation of micro-cracks in the ceramic material.

Currently, the direct rapid prototyping process for ceramics is not yet fully developed. It remains in the research phase, both domestically and internationally, and has not yet reached commercial viability.

Ceramic powder for 3D printing is a mixture of ceramic and binder powder. Due to the binder powder’s low melting point, laser sintering only melts the binder powder and binds the ceramic powder together. After laser sintering, manufacturers place the ceramic products into a temperature-controlled furnace for post-processing at higher temperatures.

The ratio of the ceramic powder to the binder powder affects the performance of the ceramic parts. A higher binder content makes sintering easier but causes more shrinkage during post-processing, affecting dimensional accuracy. Less binder makes sintering harder, and the particle size and shape significantly impact the sintering properties, with smaller, more spherical particles improving the process. Smaller, more spherical ceramic particles improve the sintering quality of the ceramic layer.

Ceramic powder in the laser direct rapid sintering of the liquid phase surface tension is large. The rapid solidification process will produce a large thermal stress, resulting in the formation of more micro-cracks. At present, the ceramic direct rapid prototyping process is not yet mature. Researchers, both domestically and internationally, are still studying it, and it has not yet been commercialized.

6 . Other 3D printing materials

Other 3D printing materials in use include colored gypsum, artificial bone powder, cellular biomaterials, and sugar.

Colored gypsum is a full-color 3D printing material based on stone bone. It is fragile, strong, and clear in color. Printing layer by layer on the powder medium produces 3D printed products with a fine granular surface texture resembling rock after processing. Curved surfaces may display a fine annual texture, making this technique commonly used for creating animation dolls and similar items.

Combining 3D printing technology with medicine and tissue engineering could create medicines and artificial organs to treat diseases. Canada is currently developing a “bone printer” that uses inkjet printer technology to transform artificial bone powder into precise bone tissue. The printer sprays bone powder onto a film and applies an acidic agent to make the film more rigid.

The University of Pennsylvania’s fresh meat printout uses lab-cultured cell medium, water-based sol as a binder, and special sugar molecules. It is still in the conceptual stage, involving bio-ink made from human cells and a special bio-paper. A computer controls the process of spraying bio-ink onto bio-paper, forming various organs through printing.

The CandyFab 4000 sprays heated sugar to create tasty desserts in various shapes.