Complete 3D Printing Materials Guide 2025 | JLYPT

Introduction
Selecting the correct additive-manufacturing (AM) material is the single highest-leverage decision in the product-development cycle. It dictates mechanical reliability, regulatory compliance, aesthetic finish, and ultimately, cost per part. JLYPT’s ISO 9001-accredited materials laboratory has characterized more than 50 industrial-grade polymers across FDM, SLA, SLS, MJF, and SLM platforms. This handbook delivers the data sheets, process-parameter windows, and three fresh case studies that engineers need to make evidence-based choices—without marketing fluff.

Table 1 — Material Quick-Selector Matrix

Table 2 — Mechanical & Thermal Property Datasheet (23 °C)

Section 1 — FDM Thermoplastics Deep-Dive

1.1 Rheology & Printability
• PETG exhibits shear-thinning above γ̇ = 100 s⁻¹; maintain volumetric flow Q ≥ 4 mm³/s to avoid shark-skin.
• PEI requires nozzle ≥ 300 °C and chamber ≥ 80 °C to prevent layer delamination (ΔT > Tg − 20 °C).

1.2 Moisture Management
• Nylon 12 absorbs 0.4 wt % in 24 h @ 50 % RH → dry at 80 °C for 4 h before printing.
• PC-FR: 0.2 wt % moisture causes surface blistering; use sealed dry-box with < 10 % RH.

1.3 Annealing Protocol
• PEI: 180 °C for 2 h in nitrogen increases HDT by 10 °C and tensile by 8 %.
• Post-anneal shrinkage: +0.2 % in-plane, +0.3 % Z—compensate in CAD.

Section 2 — SLA Resins: Chemistry & Curing

2.1 Monomer Families
• Methacrylate: high stiffness, brittle (Tough 2000).
• Epoxy-acrylate: excellent clarity, low shrink (< 0.5 %).

2.2 Biocompatibility
• ISO 10993-5 cytotoxicity pass required for surgical guides.
• Gamma sterilization stability: Clear GP retains 95 % tensile after 25 kGy.

2.3 Post-Cure Optimization
• 405 nm LED array, 60 °C, nitrogen purge for 15 min → 95 % double-bond conversion.
• Over-cure (> 30 min) increases brittleness (ΔIzod −15 %).

Section 3 — SLS & MJF Polyamide Powders

3.1 Particle Size Distribution
• D50 = 60 µm for PA12 SLS; D50 = 50 µm for MJF → smoother sidewalls Ra 4 µm vs 6 µm.

3.2 Refresh Ratio
• PA12 SLS: 50 % virgin / 50 % recycled maintains mechanical properties within ±5 %.
• MJF refresh 30 % due to thermal cycling degradation.

3.3 Vapor Smoothing
• Ethyl acetate vapor 30 s reduces Ra from 6 µm to 1 µm, sealing surface porosity.

Section 4 — Metals: SLM vs. Binder Jet

Section 5 — Cost Analysis Example

Scenario: 500 pcs, 50 cm³ each, mid-temperature enclosure.

Section 6 — Case Studies

Case 1 — High-Temp Battery Housing
Client: E-motorcycle OEM
Challenge: 120 °C service, UL94 V-0, 300-piece pilot.
Solution: PEI 9085 FDM, 0.2 mm layer, CNC milled gasket groove post-print.
Result: Passed thermal cycle 1,000 x −40 ↔ 120 °C; saved $45 k tooling.

Case 2 — Surgical Drill Guide
Client: Med-tech start-up
Challenge: Biocompatible, sterilizable, 50 mm long, 0.1 mm accuracy.
Solution: Bio-Med Clear SLA, 25 µm layer, autoclave validated.
Lead time: 3 days vs. 5-week machined PEEK.

Case 3 — Optical Lens Prototype
Client: AR headset OEM
Challenge: 50 mm diameter, λ/4 surface, 48-hour turnaround.
Solution: Clear GP SLA, 0.05 mm layer, vapor-polished, then UV-coated.
Wavefront error: 110 nm RMS vs. 60 nm target—acceptable for prototype.

Section 7 — Sustainability & Recycling

• PETG & PLA: mechanical regrind → desk organizers.
• PA12 SLS: closed-loop powder refresh 50 % reduces virgin resin by 40 %.
• Metal powder: argon inerting + sieving enables 95 % reuse after SLM.

Section 8 — FAQ

Q: Which material for outdoor UV exposure?
A: ASA or PC-UV; add 2 % HALS masterbatch for > 5 years colorfastness.

Q: Can FDM Nylon be tapped?
A: Yes—print undersized 0.15 mm, chase with tap; use heat-set inserts for > M6.

Q: SLA vs MJF dimensional accuracy?
A: SLA ±0.1 mm up to 100 mm; MJF ±0.2 mm but isotropic strength.

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