3D printing, with its unique manufacturing technology, allows us to produce unprecedented types of items and reduce costs, shorten man-hours and remove complex processes for companies. The real advantage of 3D printing technology lies in its printing materials, which can well imitate the mechanical or thermal properties of plastic and metal materials, however, this is also a major technical reason that currently restricts the development of 3D printing.
Since 3D printing manufacturing technology has completely changed the traditional manufacturing industry and principles, is a subversion of the traditional manufacturing model, therefore, 3D printing materials become the main bottleneck limiting the development of 3D printing, but also the key point and difficulty of 3D printing breakthrough innovation, only to carry out more new material development to expand the application areas of 3D printing technology. At present, 3D printing materials mainly include polymer materials, metal materials, ceramic materials and composite materials, etc.
3D printing materials are mainly divided into four kinds of materials: 3D printing polymers, 3D printing metal materials, 3D printing ceramic materials, 3D printing composite materials.
3D printing materials are an important material basis for the development of 3D printing technology, and to some extent, the development of materials determines whether 3D printing can have a wider application. At present, 3D printing materials mainly include engineering plastics, photosensitive resins, rubber-like materials, metal materials and ceramic materials, etc. In addition, colored plaster materials, artificial bone powder, cellular biological materials and food materials such as granulated sugar are also used in the field of 3D printing.
Polymeric materials are mainly divided into engineering plastics, bioplastics, thermosets, photosensitive resins, polymer gels, etc.
Metal materials mainly include ferrous and non-ferrous metals.
Ceramics and composites mainly refer to ceramic materials and composites.
Although most of the materials used for 3D printing are plastics, metal materials also have their unique uses. Next we will discuss several commonly used metal materials for 3D printing.
The metal has good mechanical properties and electrical conductivity. Ferrous materials mainly include stainless steel and high-temperature alloys.
Stainless Steel is the abbreviation of stainless acid-resistant steel, resistant to air, steam, water and other weak corrosive media or stainless steel called stainless steel; and will be resistant to chemically corrosive media (acid, alkali, salt and other chemical leaching) corrosion of steel called acid-resistant steel. Due to the differences in the chemical composition of the two and their corrosion resistance is different, ordinary stainless steel is generally not resistant to chemical media corrosion, while acid-resistant steel is generally stainless.
Stainless steel is the cheapest metal printing material, and the surface of the high-strength stainless steel products produced by 3D printing is slightly rough and has pockmarks. Stainless steel comes in a variety of different glossy and frosted surfaces and is often used for 3D printing of jewelry, functional components, and small sculptures.
High temperature alloys have excellent high temperature strength, good oxidation resistance and thermal corrosion resistance, good fatigue properties, fracture toughness and other comprehensive properties.
High-temperature alloys have become the main 3D printing material for aerospace industry applications due to their high strength, chemical stability, difficulty in molding and processing, and high cost of traditional processing processes. With the long-term research and further development of 3D printing technology, aircraft parts manufactured by 3D printing have been widely used due to their processing man-hours and cost advantages.
Non-ferrous metals including titanium, aluminum and magnesium alloys, gallium, rare precious metals.
Titanium, which looks like steel and has a silver-gray light translation, is a transition metal that has been thought to be a rare metal for some time. Titanium is not a rare metal, it accounts for about 0.42% of the total weight in the earth’s crust, 16 times more than the total of copper, nickel, lead and zinc. It ranks seventh in the world of metals, and there are more than 70 minerals that contain titanium. Titanium has high strength, low density, high hardness, high melting point and high corrosion resistance; high purity titanium has good plasticity, but becomes brittle and hard when impurities are present.
Titanium parts made using 3D printing technology are very strong and precise in size, able to produce the smallest size up to 1mm, and the mechanical properties of their parts are better than the forging process. UK-based Metalysis has successfully printed automotive parts such as impellers and turbochargers using titanium metal powders. In addition, titanium metal powder consumables in 3D printing automotive, aerospace and defense industry will have a very broad application prospects.
Due to its superior performance of light weight and high strength, magnesium-aluminum alloy has been used in a large number of applications in the light weight needs of the manufacturing industry, and it is no exception in 3D printing technology, where it is an alternative material preferred by major manufacturers.
3D printed products are becoming more and more influential in the fashion world. Jewelry designers around the world benefit the most from 3D printing rapid prototyping technology as a powerful and convenient alternative to other manufacturing methods for the creative industry. In the field of jewelry 3D printing materials, commonly used are gold, sterling silver, brass, etc.
The above is about 3D printing materials. Shanghai Truer provides a wide range of high-quality titanium and titanium aluminum alloy powder, high-temperature alloy powder, refractory alloy powder, iron-based, and high entropy alloy powder.
Additional FAQs: Classification of 4 Common Materials Used in 3D Printing
1) What are the four primary classes of 3D printing materials and their typical processes?
- Polymers (FDM/FFF, SLA/DLP, SLS), metals (LPBF/SLM, EBM, DED, MIM), ceramics (stereolithography slurries, binder jetting + sinter, robocasting), and composites (short/continuous fiber FFF, SLS-filled, photocomposites).
2) How should I choose between polymer vs. metal for functional parts?
- Start from the use case: polymers for moderate strength, chemical resistance, and cost efficiency; metals for high temperature, structural loads, and fatigue. Consider certification needs (aerospace/medical) and total cost including post-processing.
3) What role do particle size and morphology play for metal and ceramic powders?
- Spherical, narrow PSD powders improve flowability, packing, and density in powder-bed processes. Irregular particles can boost green strength in binder systems but may reduce flow and cause surface roughness.
4) Are composites just “filled plastics,” or can they match metal performance?
- Fiber-reinforced composites (e.g., CF-PEEK, CF-nylon, continuous carbon fiber) can rival aluminum in stiffness-to-weight for specific designs. However, temperature limits and through-thickness strength still trail most metals.
5) What safety considerations differ across the four classes?
- Polymers: VOCs/particulates from thermoplastics and resins (use enclosures and filtration). Metals: fine powders are reactive—use grounding, inert handling, and PPE. Ceramics: respirable silica/oxide dust control. Composites: fiber dust and resin handling; observe MSDS/SDS for each material.
2025 Industry Trends: Material Classification Focus
- Metals: Surge in aluminum and copper alloy qualifications for EV thermal components; broader availability of beta-titanium and high-γ′ Ni superalloys.
- Polymers: Growth of ESD-safe, flame-retardant UL 94 V-0 grades for factory tooling; bio-based and recycled filament share rises.
- Ceramics: Increased adoption of alumina and zirconia for dental and semiconductor fixtures with automated debind/sinter workflows.
- Composites: Wider use of continuous fiber for lightweight jigs and end-of-arm tooling; better interlayer adhesion with plasma-assisted FFF.
2025 Material Snapshot by Class (Indicative, global)
| Class | Representative Grades (2025) | Common Processes | Typical Part Strength/Temp | Cost Range (Material Only) |
|---|---|---|---|---|
| Polymers | PA12, PA11, PETG, ABS, PC, PEEK, PEKK, ESD/FR blends | FDM/FFF, SLS, SLA/DLP | 40–100 MPa tensile; up to 250–300°C (PEEK/PEKK) | $20–$350/kg |
| Metals | 316L, 17-4PH, Ti-6Al-4V, IN718, AlSi10Mg, CuCrZr | LPBF/SLM, EBM, DED, Binder Jet + Sinter | 400–1300 MPa tensile; 200–700°C service | $60–$300/kg (pre-alloyed powders) |
| Ceramics | Al2O3, ZrO2, Si3N4, SiC (R&D) | SLA-slurry, Binder Jet + Sinter, Robocasting | High hardness; >1000°C | $80–$500/kg (slurries/powders) |
| Composites | CF/GF-PA, CF-PEEK, filled-PA12, photocomposites | FFF (short/continuous fiber), SLS, SLA | Up to 150–300 MPa (directional); 120–250°C | $50–$600/kg |
Additional indicators:
- Qualified AM metal alloys grew from ~35 (2022) to ~60+ (2025), led by aluminum, copper, and beta-Ti.
- Recycled polymer feedstock share in FFF/SLS surpasses 15% in 2025 for tooling and consumer goods.
- Dental zirconia AM volumes up ~18% YoY due to automated CAM-to-sinter pipelines.
Sources:
- ASTM/ISO AM standards catalogs: https://www.astm.org and https://www.iso.org
- Wohlers/ContextAM market briefs (industry reports)
- FDA/EMA guidance for medical AM materials: https://www.fda.gov and https://www.ema.europa.eu
- NIST AM Bench and materials datasets: https://www.nist.gov/ambench
Latest Research Cases
Case Study 1: CF-PEEK Composite Brackets for Aerospace Interiors (2025)
Background: An aerospace tier-1 sought metal replacement for cabin brackets to reduce weight while meeting flammability and strength specs.
Solution: Printed continuous carbon fiber reinforced PEEK using heated-chamber FFF; optimized layup with topology optimization; applied plasma surface treatment for bonding.
Results: 42% weight reduction vs. machined aluminum, maintained factor of safety >1.5, passed FAR 25.853 flammability; cost down 18% at 200-unit batches.
Case Study 2: Binder Jetting of 316L with Recycled Powder Fraction (2024)
Background: An industrial OEM aimed to lower powder costs and waste in stainless steel production parts.
Solution: Introduced 20% recycled -20/+45 µm fraction blended with virgin powder; tuned debind and sinter curves and applied post-HIP for critical parts.
Results: Achieved 98.5–99.3% relative density, yield strength within 3% of all-virgin baseline, material cost reduced 14%, no increase in dimensional nonconformance over 1,200 parts.
Expert Opinions
- Dr. Karla J. Boehm, Materials Scientist, NIST
- Viewpoint: “Powder morphology and oxygen/nitrogen control are now as decisive as alloy choice for metal AM, particularly when comparing classifications across polymers, metals, and ceramics.”
- Prof. Filippo Berto, Chair of Fracture Mechanics, Norwegian University of Science and Technology (NTNU)
- Viewpoint: “For composite AM, interlaminar fracture and load-path design dominate; continuous fiber steering unlocks metal-like stiffness-to-weight in targeted regions.”
- Sarah Goehrke, AM Industry Analyst
- Viewpoint: “In 2025, buyers are classifying materials not only by base chemistry but by certification pathway—UL, FDA, aerospace AMS—because qualification cost defines ROI as much as raw material price.”
Practical Tools and Resources
- ISO/ASTM 52900 and 52907: AM fundamentals and metal powder feedstock specs. https://www.iso.org
- ASTM F42 and D20 committees: Standards for polymers, metals, and composites in AM. https://www.astm.org
- MPIF design guides for metal powders and sintering. https://www.mpif.org
- OSHA/NIOSH guidance for polymer, metal, and ceramic powder safety. https://www.osha.gov and https://www.cdc.gov/niosh
- MatWeb materials database for datasheets across the four classes. https://www.matweb.com
- Senvol Database for AM materials and machine-process compatibility. https://senvol.com
- NIST AM-Bench measurement science resources and datasets. https://www.nist.gov/ambench
- UL 94 and FAR 25.853 references for flame and smoke toxicity for polymer/composite applications. https://www.ul.com
Last updated: 2025-08-25
Changelog: Added 5 FAQs tailored to the four material classes; inserted 2025 trend table and indicators; provided two recent case studies; included expert opinions; compiled practical tools/resources with authoritative links
Next review date & triggers: 2026-02-01 or earlier if major AM materials standards (ASTM/ISO) update, new FDA/UL certifications impact classifications, or market data shows >10% shift in alloy/polymer adoption mix
