Strong and Durable 3D Printing Materials

When you need to print parts that can withstand harsh industrial conditions, you’ll want to use strong 3D printing materials. But it isn’t always clear what the best choice is.

It would be nice if there were a single, universal metric that described material strength or durability, and you could simply choose the “most durable" 3D printing material for your application. However, the reality is a lot more complex:

The chart above shows only a sample of the materials which Stratasys offers, which is a subset of all polymer 3D printing materials, which is of course a subset of materials in general.

This chart also only shows tensile strength, impact strength, and heat deflection temperature of these materials. There are several other ways to measure material strength and toughness.

Selecting the right polymer for functional prototyping or production requires more than just comparing tensile strength or heat resistance. Different applications call for different mechanical priorities, and knowing how to interpret these values is key.

In the sections below, we’ll define core performance metrics—like strength, stiffness, and toughness—and compare how they vary across 3D printing technologies. This will help you navigate the trade-offs and identify the best fit for your application.

Defining Material Strength and Toughness for 3D Printing Materials

Strength, stiffness, and toughness are all important characteristics of a durable material. But what do these terms actually mean? How do you pick which to prioritize when choosing a durable 3D printing material?

• Stiffness: How well a material can resist bending or flexing (technically, “deformation”)
• Toughness: The ability of a material to absorb energy and plastically deform without fracturing.
• Strength: The ability of a material to withstand an applied force without failure (either permanent deformation or fracture). Key metrics include:
  
  
  • Yield Strength: The stress at which a material begins to deform plastically.
  • Ultimate Tensile Strength: The maximum stress a material can withstand while being stretched or pulled.

When you need durable parts, choose a 3D printing material based on the properties above to ensure the reliability and durability of your manufactured parts. Aside from material specifications, the underlying 3D printing technology should also have a significant bearing on your decision.

So, let’s take a look at strong 3D printing materials in each of the following categories:

• Strong FDM^® filaments
• Strong PolyJet™ materials
• Strong SAF^® (PBF) materials
• Strong P3™ DLP materials

Strong FDM Filaments

When you think of “strong 3D printing materials,” FDM filaments are probably first to come to mind, which makes sense. Fused deposition modeling is known for some of the strongest 3D printing filaments around.

You might notice that there are clear tradeoffs here. If you want the most robust filament when it comes to being dropped, or general wear and tear, you might choose PC-ABS. If you need some amount of ductility, Nylon 12 looks better. If you require very high strength and temperature, ULTEM™ is likely best.

Case Study: EANT GmbH

An engineering firm used Nylon 12CF, a carbon-fiber material, to manufacture a lightweight, high-strength support mount for maritime satellite antennae. The material's high tensile strength and rigidity, combined with the large build chamber of the F900 printer, made it an ideal choice for this application. The 3D printed antenna support mount decreased production cost by 20%, reduced the production time by 75%, and lowered the part’s weight by 38%.

Another thing to note when it comes to FDM: It is generally not isotropic. It is stronger within each layer than it is across the printed layers. For this reason, you can usually find two separate specifications, one for XZ strength and one for ZX strength. (The specs given above are for XZ direction. You can find datasheets with full specifications here.)

When to Use Strong FDM Materials

FDM technology is a classic example of a min-max approach. If you need to print something strong and/or large, it is often the best solution. On top of that, FDM machines are typically among the easiest to integrate and learn to use.

When Not to Use FDM Technology

If appearance is critical, FDM technology might not be the best solution as it tends to leave visible layer lines on the printed part. FDM is also unsuitable for printing parts with several colors, materials, or very high-resolution delicate features.

Strong PolyJet Materials

PolyJet technology, historically, has been viewed as the total opposite side of the spectrum, when compared with FDM. If FDM is optimized for strength, PolyJet is favored for its aesthetics.

PolyJet can print multiple colors and materials in a single print. It boasts very high resolution (layer thickness down to 14 μm).

When it comes to toughness, however, PolyJet is not usually the first choice. This has changed somewhat with the recent release of the ToughONE material, however. ToughONE provides a unique combination of strength, toughness, and high surface finish. It can be used with color and multiple materials for functional prototyping and even production of final parts.

When to Use PolyJet Technology

PolyJet is ideal for applications where high precision, fine details, and a smooth surface finish are critical. It is particularly well-suited for:

• Functional Prototyping: Creating detailed and accurate prototypes with multiple colors and materials, which also withstand mechanical testing and functional use, such as automotive parts or consumer electronics housings.
• Production Aids: Manufacturing final parts that require both strength and a high-quality finish, such as custom jigs, fixtures, and tooling components.
• Consumer Products: Manufacturing parts that require a high-quality finish and intricate details.

When Not to Use PolyJet Technology

• High-Temperature Environments: Applications where parts are exposed to high temperatures for extended periods.
• Large Parts: Producing large parts may be more challenging and less cost-effective with PolyJet compared to other technologies like FDM or SAF.

Strong SAF (PBF) Materials

SAF selective absorption fusion is a type of powder bed fusion (PBF) which also boasts some strong materials:

Here, too, there’s a clear distinction between 3D materials that are very stiff (high flexural strength) and rugged (high impact). Resistance to temperature is an important factor here as well.

Case Study: 3D Composites

A manufacturing service bureau used SAF to produce parts for the aerospace industry, including manufacturing jigs, fixtures, tooling, and production parts. 3D composites preferred Nylon PA12, for its rigidity, feature resolution, and strength. SAF allowed for high-volume production with consistent quality, reducing cost per part and lead times, which enabled the company to meet tight production deadlines.

When to Use SAF Technology

SAF is known for its high repeatability and low cost per part. Hundreds of parts can be printed in a single 12-hour print, enabling annual manufacturing volumes into the tens of thousands which, along with excellent strength specifications, makes it particularly suited for mid-to-high-volume production.

When Not to Use SAF Technology

SAF is not recommended for applications which require a very smooth finish. In those cases, you may be better off choosing a PolyJet, SLA, or P3 DLP solution.

Strong P3 DLP Materials

P3 DLP printers are known for their rare combination of excellent strength and material performance, along with exceptional surface finish and accuracy. This makes them perfect for production aids and other low-volume manufacturing, where the parts need to be strong enough to handle daily use, while also requiring a high level of surface finish and precision.

When Not to Use P3 DLP

We can skip the “when to use” section here, as it works well in so many cases it’s actually simpler to just say when not to use it. There are essentially only two areas where P3 DLP underperforms:

1. Large part size: DLP build size is typically on the small side. If you need to print large parts, you might prefer FDM or SLA.
2. Multicolor, multi-material: Full color and multi-material applications like prototyping and short-run test batches are really only possible with PolyJet.
   
   

How to Choose the Best Strong 3D Printing Material

Once you have a good idea which 3D printing technology will best suit your needs, you still have the task of selecting the right material for AM. You should consider the material’s various properties:

• Mechanical Properties:
  • Strength: Ability to withstand applied forces.
  • Toughness: Resistance to crack propagation.
  • Fatigue Resistance: Ability to withstand repeated loading.

• Thermal Properties:
  • Heat Resistance: Ability to maintain properties at elevated temperatures.
  • Thermal Expansion: Change in dimensions with temperature changes

• Chemical Properties:
  • Corrosion Resistance: Ability to withstand chemical attack.
  • Chemical Stability: Resistance to degradation by chemicals.
• Cost and Availability: Economic feasibility and material availability.

Conclusion

If you’re ever curious about possible material specs for your next project, I can give you two simple pieces of advice:

1. First, check out this material wizard. As you narrow down possible materials based on your needs, you may quickly discover which printing technology will work for you.
2. And of course, our experts are here to help you, every step of the way. Don’t hesitate to reach out to discuss all the nitty gritty details of your project. That’s what we’re here for.