Strengths and weaknesses of the 3 most common 3D printing materials

In the world of large format additive manufacturing (LFAM), the types of thermoplastic materials selected, and the parameters used in production can significantly affect the performance, durability, and cost-efficiency of the final part. Discover how Caracol leverages the most commonly used resins – ABS, PETG, and PC – to deliver top-tier large-format 3D printing solutions for the most demanding industrial applications on the market.

Large-scale thermoplastic 3D printing is revolutionizing manufacturing, offering unparalleled flexibility, efficiency, and material performance. Among the most common 3D printing materials, PETG, ABS and PC stand out due to their superior mechanical properties and versatility. At Caracol, the R&D team ensures the highest material quality by qualifying and optimizing the best types of thermoplastic materials for our Heron AM robotic technology, accurately selected and proposed to customers by our Application Engineering and Production teams based on their manufacturing needs.

PETG: balance between strength and printability

Caracol’s materials portfolio includes rPETG (recycled) and rPETG + 30% Glass Fiber. This stunning thermoplastic 3D printing material
is perfect for finished parts in creative sectors or basic industrial requirements as it ensures flexibility across applications, whether you need durability or enhanced stiffness and UV resistance for outdoor use.

Strengths:

• In its fiber reinforced version, the material shows minimal shrinkage during the printing process, allowing for high dimensional accuracy and reducing the risk of warping in thermoplastic 3D printers, even when producing large-scale components.
• PETG offers a robust combination of strength and flexibility, which facilitates easy post-processing operations, including cutting, drilling, and finishing, without compromising the part’s structural integrity.
• The fiber-reinforced variant makes PETG UV resistance, making it an ideal choice for outdoor applications where prolonged exposure to sunlight could otherwise degrade material properties.

Weaknesses:

• PETG has limited heat resistance, which restricts its use in high-temperature environments or applications subjected to significant thermal stress. A recommended alternative for such conditions is PC CF, this thermoplastic 3D printing material provides superior thermal stability and mechanical robustness.

ABS: a versatile industrial material perfect for transportation industry finished parts and jigs

Caracol qualified ABS with 20% glass-fiber, 20% carbon fiber or 20% recycled carbon fiber. These types of thermoplastic materials
are ideal for marine, aerospace, and automotive sectors, offering strength and durability.

Strengths:

• Good impact resistance, ensuring durability in applications where mechanical stress and shock absorption are crucial, such as marine or automotive components subject to constant vibrations and force.
• The material provides outstanding thermal stability, which allows it to maintain its dimensional accuracy even under fluctuating temperature conditions, making it suitable for precision components and tooling.
• Excellent heat resistance, maintaining performance even at high temperatures for extended periods without significant deformation.

Weaknesses:

• Recycling ABS poses challenges, but advances in material processing are continuously improving its recyclability. Caracol actively integrates recycled ABS into its thermoplastic 3D printing portfolio to minimize environmental impact and promote sustainable manufacturing solutions.

PC: the ultimate high-performance material

Caracol offers PC + 20% carbon fiber reinforced, making it ideal for high-performance applications requiring strength, heat resistance, and stability.

Strengths:

• PC possesses exceptional mechanical strength, which enables it to withstand high structural loads and resist deformation under mechanical stress, making it suitable for applications requiring superior durability.
• This composite material offers industry-leading high-temperature resistance, allowing it to operate effectively at temperatures up to 135°C, making it the preferred choice for autoclave tooling and applications exposed to intense heat conditions.
• PC ensures remarkable dimensional stability, which guarantees that components printed with this material maintain precise tolerances and structural integrity, even when subjected to mechanical stress or extreme temperature variations.

Weaknesses:

• PC can become brittle when used in thin-walled sections, increasing the likelihood of cracking or mechanical failure under impact. To mitigate this, reinforcing critical areas in the part design and adjusting layer adhesion settings during printing can significantly enhance the material’s performance.
• The material is relatively costly compared to conventional thermoplastics, but its exceptional durability, long-term performance, and reduced need for frequent replacements justify the investment for high-performance applications.

Caracol’s approach to materials qualification: innovation and sustainability

Caracol’s Heron AM robotic platform is designed to support a diverse range of thermoplastic materials in pellet form, from the most common 3D printing material to recycled polymers to high-performance composites, allowing companies to optimize their production processes with efficiency and reliability. With a dedicated Material Lab, Caracol leads the industry in testing and qualifying materials to ensure their suitability for a variety of demanding applications. The continuous research and validation process allows Heron AM to integrate cutting-edge materials, pushing the boundaries of what is possible in additive manufacturing.

Caracol’s commitment to material innovation extends across multiple industries, ensuring that every material selected meets stringent performance and sustainability standards. By constantly refining and expanding its portfolio, Caracol’s thermoplastic 3D printer drives the evolution of industrial manufacturing, making it more adaptable, efficient, and environmentally responsible.

The journey toward innovation never stops, as Caracol remains dedicated to discovering new solutions that will shape the future of industrial production thanks to large format additive manufacturing.

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