Thermoplastics
Material Introduction
Thermoplastics represent the most versatile and widely used material category in modern additive manufacturing. Their ability to soften when heated and solidify upon cooling enables efficient shaping, reprocessing, and high-throughput fabrication. In 3D printing, thermoplastics support technologies such as FDM/FFF, SLS, and industrial polymer laser sintering, offering an excellent balance of mechanical performance, chemical stability, and design flexibility. Through Neway AeroTech’s advanced thermoplastic 3D printing, engineers can produce prototypes, functional components, housings, jigs, fixtures, and end-use industrial parts with exceptional dimensional accuracy. Thermoplastics encompass a range of materials, from basic PLA and ABS to high-performance engineering polymers such as Nylon, TPU, PC, PETG, and PEEK, each offering unique combinations of strength, heat resistance, flexibility, and durability suitable for various applications, including aerospace, automotive, electronics, tooling, and consumer products.
International Names or Representative Polymers
Region | Common Name | Representative Grades |
|---|---|---|
USA | Thermoplastics | PLA, ABS, Nylon, TPU |
Europe | Engineering Plastics | PA12, PETG, PC |
Japan | Industrial Polymers | PEEK, PC, ABS |
China | 热塑性塑料 | PLA, ABS, PA, TPU |
Industry Classification | Polymer Materials | Commodity, Engineering, High-Performance |
Alternative Material Options
When thermoplastics do not fully meet performance requirements, numerous other materials can be considered based on factors such as strength, temperature resistance, chemical resistance, or dimensional stability. For higher mechanical performance or chemical resistance, engineering plastics such as high-performance plastics and polycarbonate offer improved toughness and heat tolerance. When metal-like strength is needed, engineers may leverage industrial metal AM such as stainless steel 3D printing or lightweight alloys like aluminum 3D printing. For extremely high-temperature environments, nickel alloys such as Hastelloy or titanium materials like Ti-13V-11Cr-3Al (TC11) deliver superior thermal stability. Flexible and rubber-like components can be produced using elastomers like TPU. These alternatives ensure that designers can match material performance precisely to functional and environmental requirements.
Design Purpose
Thermoplastics were developed to deliver re-processability, lightweight structure, chemical resistance, and manufacturability at moderate temperatures. Their ability to melt and reform repeatedly makes them ideal for high-efficiency forming processes. In 3D printing, the design intention expands to enabling rapid prototyping, cost-effective tooling, lightweight functional components, and flexible design testing. Engineering-grade thermoplastics provide significant improvements in strength, fatigue resistance, thermal stability, and toughness, supporting demanding industries that require optimized geometry and reliable performance.
Chemical Composition (Generalized)
Polymer Type | Primary Composition |
|---|---|
PLA | Polylactic acid (biopolymer) |
ABS | Acrylonitrile, Butadiene, Styrene |
Nylon (PA) | Polyamide chains |
PETG | Polyethylene Terephthalate Glycol |
TPU | Thermoplastic Polyurethane |
PC | Polycarbonate polymer chain |
PEEK | Polyether Ether Ketone aromatic chain |
Physical Properties (Typical Ranges)
Property | Value |
|---|---|
Density | 1.0–1.3 g/cm³ |
Melting Point | 60–340°C (depends on polymer) |
Thermal Conductivity | 0.2–0.3 W/m·K |
Heat Deflection Temp | 50–250°C |
Water Absorption | Low to moderate |
Mechanical Properties (Typical Ranges)
Property | Value |
|---|---|
Tensile Strength | 30–100 MPa |
Flexural Strength | 40–150 MPa |
Elongation at Break | 3–500% (depending on polymer) |
Hardness | Shore A 80 to Shore D 80 |
Impact Resistance | Moderate to very high |
Key Material Characteristics
Wide range of mechanical properties suitable for prototypes and functional parts
Lightweight and easy to process with low energy consumption
Excellent adaptability for FDM, SLS, and polymer laser sintering
Good chemical resistance depending on polymer family
Supports flexible, rigid, transparent, or high-performance applications
Suitable for large-scale printing and complex geometries
Includes biodegradable options such as PLA for sustainable manufacturing
High fatigue resistance in materials like Nylon and TPU
Offers excellent surface finish options through polishing or vapor smoothing
Cost-effective for both manufacturing iterations and series production
Manufacturability in Different Processes
Additive manufacturing: Ideal for FDM/FFF and SLS using thermoplastic AM.
Multi-material printing: Supported by flexible polymers such as TPU.
High-performance AM: Materials like PEEK require controlled thermal chambers.
Prototyping: Fast printing with materials like PLA.
Functional parts: Strong engineering polymers such as Nylon or reinforced composites.
CNC machining: Many thermoplastics can be machined for finishing operations.
Molding: Thermoplastics inherently support injection molding, benefiting design for AM-to-mold transitions.
Resin alternatives: Certain shapes can shift to photopolymer resins when higher detail is required.
Suitable Post-Processing Methods
Surface smoothing through vapor polishing, especially for ABS
Annealing for dimensional stability and improved strength
Painting, coating, or plating for appearance enhancements
Machining and drilling for tight-tolerance adjustments
Thermal conditioning to reduce residual stresses
Hot Isostatic Pressing is not applicable, but polymers may undergo thermal stabilization
Nondestructive inspection via material testing and analysis for structural consistency
Dyeing or color finishing for SLS Nylon components
Common Industries and Applications
Consumer electronics housings and structural components
Aerospace interior parts and non-load-bearing assemblies
Automotive dashboards, clips, fixtures, and lightweight covers
Medical models, guides, and prototyping tools
Industrial jigs, fixtures, and packaging components
Robotics, automation housings, and sensor enclosures
When to Choose This Material
When rapid prototyping is required with low material cost
When lightweight, non-metallic components are adequate for functionality
When flexibility, transparency, or soft-touch properties are needed
When chemical resistance or fatigue performance is essential
When transitioning from prototype to mass-production injection molding
When environmental sustainability or biodegradability is preferred (PLA)
When producing complex geometries with minimal design restrictions
When high-performance polymers are required for engineering-grade applications
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