3D printing technology as an emerging cutting-edge technology is profoundly changing the way humans are produced. The use of 3D printing in various industries has also led to the application and development of more and more 3D printing materials. In this article, we will talk about what are the materials used for 3D printing?
More than 200 materials are now available for 3D printing, and more will be used in the foreseeable future as the technology is used in an increasing number of industries. Of the more than 200 materials used in 3D printing, metals, polymers, ceramics, composites, and biomaterials are currently the most common materials used for 3D printing. In this article, we will give a brief overview of the various types of materials and applications for 3D printing.
Metallic Materials
The rapid development of metallic materials in the field of 3D printing stems from the demand for aerospace, automotive, electronics, etc. Among the many metal materials, titanium alloys are the most widely used, followed by aluminum alloys, stainless steel, high-temperature alloys, and high-entropy alloys.
Titanium alloy is a material with high strength, good corrosion resistance, and high heat resistance, therefore titanium alloy is mainly used to make aircraft engine pressurized parts, followed by structural parts for rockets, missiles, and high-speed aircraft to apply. Also, 3D printed titanium alloys are used in biomedical, 3D printed titanium stents due to their low density, high strength, and lightweight. And the use of titanium alloys in biomedical applications has become quite mature and widespread.
Stainless steel is characterized by its chemical resistance, high-temperature resistance, and good mechanical properties and is often used as a 3D printing material for jewelry, functional components, and small sculptures due to its good powder formability, simple preparation process, and low cost.
High-temperature alloys are widely used in aerospace and other fields due to their high strength at high temperatures and resistance to corrosion. Commonly used grades of nickel-based alloys for 3D printing include Inconel 625, Inconel 718, and Inconel 939.
Precious metals such as magnesium and aluminum alloys and gold and silver are also used more widely in 3D printing.
Polymeric Materials
Polymers have long been a popular material for 3D printing, widely used for their high strength, performance, and low cost. Currently, the most commonly used are ABS, PA, and photosensitive resin UV.
Ceramic Materials
Aluminosilicate ceramic powder is a class of ceramic powder material for 3D printing. It is impervious to water, heat resistant, and recyclable, and is therefore widely used in tableware, artwork, and other applications.
Composite Materials
Composites mainly include metal matrix composites as well as non-metal matrix composites. Due to the excellent heat and chemical resistance of complex-shaped parts printed on reinforced polymer materials, they are mostly used in aerospace and other applications.
These are just a few of the common 3D printing materials, but of course, there is also a class of bionic 3D printing materials that allow for biological scaffold printing and cell printing.
It is conceivable that along with the increasing abundance of 3D printing materials and the rapid development of 3D printing technology. 3D printing materials will be used in more and more fields and will develop towards better mechanical properties, higher processing performance, and more diversification.
Additional FAQs on 3D Printing Materials
1) What factors determine which 3D printing process to use for a material?
- Key drivers: melting/softening behavior, reactivity/oxidation, viscosity (for resins and pastes), required part properties, dimensional tolerances, and cost. For example, titanium fits laser powder bed fusion (LPBF) with inert gas, while ABS and PA suit FDM/SLS.
2) How do metal powder specifications impact print quality?
- Particle size distribution (typically D10–D90 ≈ 15–45 μm for LPBF), sphericity, low interstitials (O/N/H), and low contamination directly affect flowability, density, and mechanical properties. Reference: ISO/ASTM 52907 for feedstock.
3) Are biocompatible materials available for medical 3D printing?
- Yes. Titanium alloys (Ti‑6Al‑4V ELI), cobalt‑chromium, PEEK/PEKK, medical‑grade photopolymers, and bio‑inks (hydrogels with cells) are used for implants, guides, and tissue scaffolds, subject to ISO 10993 and FDA/CE pathways.
4) What’s the difference between thermoplastics used in FDM vs. SLS?
- FDM uses filament that melts and extrudes (e.g., PLA, ABS, PETG, PEI/ULTEM), while SLS fuses powder beds of PA12, PA11, TPU, and filled nylons. SLS typically yields better isotropy and complex geometries without supports.
5) Can composites be 3D printed to replace metals?
- In some cases. Carbon‑fiber or glass‑fiber reinforced PA/PEEK printed with continuous fibers can approach aluminum‑like stiffness/strength on a weight basis, suitable for jigs, fixtures, and some end‑use parts; temperature and impact limits still apply.
2025 Industry Trends in 3D Printing Materials
- Blue/green laser LPBF broadens copper/aluminum applications in e‑mobility and thermal management.
- Medical polymers mature: sterilizable high‑performance polymers (PEEK/PEKK, PPSU) gain validated print profiles and regulatory guidance.
- Sustainable materials: bio‑based nylons (PA11 from castor), recycled PETG/PA, and closed‑loop powder handling with material passports.
- Binder jetting scaling: steel and copper binder‑jet with refined sinter/HIP achieves 95–99% density for large, cost‑sensitive parts.
- High‑entropy and gradient alloys: research moves toward printable, compositionally graded metals for site‑specific properties.
| 2025 Metric (Material + Process) | Typical Range/Value | Why it matters | Source |
|---|---|---|---|
| LPBF powder PSD (most metals) | D10–D90 ≈ 15–45 μm | Stable recoating, low porosity | ISO/ASTM 52907 |
| Ti‑6Al‑4V ELI powder oxygen | ≤0.13 wt% | Fatigue/ductility in implants | ASTM F136/F3001 |
| SLS PA12 tensile strength | 45–55 MPa (XZ); 40–50 MPa (ZX) | Design allowables | OEM datasheets/ASM |
| FDM CF‑PA tensile modulus | 8–20 GPa (with continuous CF) | Metal replacement potential | Vendor tech notes |
| Binder‑jetted 17‑4PH density | 97–99% after sinter/HIP | Tooling/production parts | Vendor case studies |
| Copper LPBF conductivity | 80–95% IACS with green lasers | Thermal/electrical performance | Peer‑reviewed AM studies |
Authoritative references and further reading:
- ISO/ASTM 52907 (AM feedstock): https://www.iso.org
- ASTM F2924/F3001/F3055/F3184 (AM materials): https://www.astm.org
- NIST AM Bench datasets: https://www.nist.gov
- FDA guidance on additive manufacturing of medical devices: https://www.fda.gov
Latest Research Cases
Case Study 1: Green‑Laser LPBF of Pure Copper Heat Sinks for Power Electronics (2025)
Background: An inverter manufacturer needed compact, high‑conductivity heat sinks; IR lasers struggled with Cu reflectivity.
Solution: Adopted 515 nm green‑laser LPBF with high‑sphericity gas‑atomized Cu powder (15–45 μm), inert chamber with O2 < 100 ppm, and scan strategies to reduce spatter.
Results: 90–95% IACS conductivity, porosity <0.2%, 14% lower junction temperature vs. machined baseline; 30% recycled powder blend maintained specs over 6 cycles.
Case Study 2: SLS PA11‑CF Ducts for eVTOL Environmental Control Systems (2024)
Background: Aerial mobility OEM sought lightweight, chemical‑resistant ECS ducts with complex routing.
Solution: Printed bio‑based PA11 with chopped carbon fiber on SLS; post‑processed with vapor smoothing and QA via CT sampling.
Results: 22% mass reduction vs. aluminum tubes, impact strength improved 18% over PA12 baseline, passed DO‑160 chemical exposure tests.
Expert Opinions
- Prof. John Hart, Professor of Mechanical Engineering, MIT
Key viewpoint: “Linking in‑situ build data with powder passports will set the norm for serial qualification across metals and polymers.” - Dr. Laura Schmidt, Head of Additive Manufacturing, Fraunhofer IAPT
Key viewpoint: “Green and blue lasers are transforming copper and aluminum from niche to production materials in LPBF.” - Dr. Dieter Schirmacher, Materials Scientist, Medical AM Consultant
Key viewpoint: “Validated print parameters and sterilization pathways for PEEK/PEKK are accelerating adoption in load‑bearing implants.”
Citations for expert profiles:
- MIT: https://meche.mit.edu
- Fraunhofer IAPT: https://www.iapt.fraunhofer.de
Practical Tools and Resources
- Standards and safety
- ISO/ASTM 52907; ASTM F2924/F3001/F3055/F3184; ISO 10993 (biocompatibility); NFPA 484 (combustible metals)
- Powder and filament QC
- LECO O/N/H analyzers: https://www.leco.com
- Laser diffraction PSD, SEM morphology, moisture analyzers
- Filament roundness/diameter gauges for FDM
- Design and simulation
- Ansys Additive, Simufact Additive, Autodesk Netfabb; nTopology for lattices and conformal cooling
- Market and datasets
- Senvol Database (machines/materials): https://senvol.com/database
- NIST AM Bench datasets: https://www.nist.gov
Last updated: 2025-08-21
Changelog: Added 5 FAQs, a 2025 trends table with metrics and sources, two new case studies (copper LPBF and PA11‑CF SLS), expert viewpoints with citations, and practical tools/resources.
Next review date & triggers: 2026-02-01 or earlier if ISO/ASTM standards update, major OEMs publish new copper/aluminum LPBF datasets, or medical AM material guidance changes.
