Additive Manufacturing Material
Additive Manufacturing (AM) or additive layer manufacturing is a method of manufacturing that creates durable and lightweight parts. Additive manufacturing uses Computer-Aided-Design (CAD) or a 3D model to direct hardware to build an object in successive layers. The CAD drawing acts as a set of instructions or blueprints, illustrating all the intricacies of the product being made. These blueprints instruct the machine where and when to place the material. Complex objects can be produced in this manner without the need to join together separate parts. Some examples of products made using additive manufacturing technologies include surgical implants, parts for aerospace and defense industries, automotive parts and rapid prototypes. Additive manufacturing is used by vastly different industries due to the wide variety of materials to choose from to create industry-specific products and parts.
Three primary types of materials can be used for additive manufacturing: polymers, metals and ceramics. These materials are commonly available in powder form or wire feedstock. Additional materials include paper, adhesive paper, chocolates/food and polymer/adhesive sheets for Laminated Object Manufacturing (LOM). It is possible to print nearly any material using the additive manufacturing method of layering. However, the process can alter the material’s microstructure due to the high heat and pressure used during AM. The chosen material can also affect the finish. Therefore, the material’s characteristics may not be the same during pre-manufacture as they were during post-manufacture.
Polymers
Polymers are common plastics, which include Acrylonitrile Butadiene Styrene (ABS) and Polycarbonate (PC). This category also contains waxes, epoxy-based resins and structural polymers. When heated, polymers can become soft and will regain firmness after they are cooled. Polymer powders can be mixed with polymers or other materials to create alloys that have different structural and aesthetic properties. Polymers used in AM include / /
- ABS (Acrylonitrile Butadiene Styrene)
- PLA (Polylactide), soft PLA
- PC (Polycarbonate)
- Polyamide (Nylon)
- Nylon 12 (Tensile strength 45 MPA)
- Epoxy Resin
- Wax
- Photopolymer Resins
Metals
Different metals can be used for additive manufacturing. Metal for additive manufacturing begins in two forms—powder and filament. Parts made retain superior mechanical properties. Metals used in AM include / /
- Aluminum Alloys
- Cobalt-Based Alloys
- Tool Steels
- Nickel-Based Alloys
- Stainless Steels
- Titanium Alloys
- Precious Metals (gold, silver)
- Copper Alloys
Additive Manufacturing Parts & Images
PolyJet Materials
| TYPE | MATERIALS | DESCRIPTION |
| Simulated ABS | Digital ABS Plus (Ivory) | - Simulates ABS plastics by combining strength with high temperature resistance
- Digital ABS PlusTM offers enhanced dimensional stability for thin-walled parts
- Ideal for functional prototypes, snap-fit parts for high or low temperature usage, electrical parts, castings, mobile telephone casings, engine parts & covers
|
| Transparent | Vero Clear | - Print clear & tinted parts and prototypes with VeroClearTM & RGD720
- Combine with color materials for stunning transparent shades
- Ideal for form & fit testing of see-through parts like glass, consumer products, eyewear, light covers and cases, visualization of liquid flow, medical applications, artistic & exhibition modeling
|
| Rigid Opaque | Vero Pure White, Vero Black Plus, Vero White Plus, Vero Yellow, Vero Cyan, Vero Magenta, Vero Blue | - Brilliant color options for unprecedented design freedom
- Combine with rubber-like materials for overmolding, soft touch handles & more
- Ideal for fit & form testing, moving & assembled parts, sales, marketing & exhibition models, assembly of electronic components & silicone molding
|
| Simulated Polypropylene | Rigur (White) | - Simulates the appearance & functionality of polypropylene
- Ideal for prototyping containers & packaging, flexible snap-fit applications & living hinges, toys, battery cases, laboratory equipment, loudspeakers & automotive components
|
| Rubber-like | Agilus30 (Clear), TangoBlack+ | - Offers various levels of elastomer characteristics
- Combine with rigid materials for a variety of Shore A values, from Shore A 27 to Shore A 95
- Ideal for rubber surrounds & overmolding, soft-touch coatings & nonslip surfaces, knobs, grips, pulls, handles, gaskets, seals, hoses, footwear & marketing models
|
| Digital Materials | Predetermined blends of the above materials | - Wide range of flexibility, from Shore A 27 to Shore A 95
- Rigid materials ranging from simulated standard plastics to the toughness & temperature resistance of Digital ABS Plus TM
- Vibrant colors in rigid or flexible materials, with over 500,000 color options
- Available on PolyJet multi-jetting 3D printers
|
*Parts over 250mm in any dimension require quote review.
Additional Flexible 3D Printing Options / / TPU 92A for FDM, TPU 88A for SLS & Urethane Casting
Order Material Samples // Keychains & Kits
PolyJet Parts In As Soon As Same Day / / Get A Quote
Stereolithography (SLA) Material
Stereolithography (SLA) technology is ideal for high-resolution finishes regarding medium- to large-sized parts. It is an extremely cost-effective solution for creating durable, aesthetically pleasing parts of considerable size on a tight deadline. SLA resins with extremely high heat deflection are available and are excellent materials for building molds or inserts.
How does the stereolithography technology work? SLA cures photopolymer resin with an ultraviolet laser. The laser traces a shape dictated by the original file across the surface of the resin bath. The resin that is touched by the laser hardens, then the build platform descends in the resin bath. The process is then repeated until the entire part is complete.
SLA offers a combination of high-quality resolution and surface finishes at large volume. SLA is also very effective at faithfully capturing the intricacies of even the most complex parts. Clear 3D printed SLA resins can achieve colorless clarity with additional post processing to mimic clear plastics. SLA specializes in creating parts that are highly cost-intensive to produce using any other method of manufacturing, and are consistently used for trade show models, aesthetic parts and snap fits/functional assemblies.
SLA 3D Printed Parts and Images
FDM Materials
| MATERIALS | DESCRIPTION |
TPU 92A
(thermoplastic polyurethane elastomer) | - Accurate elastomer parts with high elongation
- Superior toughness & abrasion resistance
- Wide variety of applications including flexible hoses, tubes, air ducts & vibration dampeners
|
Antero™ 800NA
(polyetherketoneketone) | - High heat & chemical resistance
- Low outgassing & high dimensional stability
- Excellent strength, toughness & wear-resistant properties
|
ULTEM™ 1010 resin
(polyetherimide) | - Certified food safety & bio-compatibility
- Highest heat resistance, chemical resistance & tensile strength
- Outstanding strength & thermal stability
|
ULTEM 9085 resin
(polyetherimide) | - FST (flame, smoke, toxicity)-certified thermoplastic
- High heat & chemical resistance; highest flexural strength
- Ideal for commercial transportation applications such as airplanes, buses, trains & boats
|
FDM Nylon 12™
(polyamide 12) | - Toughest nylon in additive manufacturing
- Excellent for repetitive snap fits, press fit inserts & fatigue-resistance applications
- Simple, clean process – free of powders
|
FDM Nylon 12CF™
(polyamide 12CF) | - Carbon-filled thermoplastic with excellent structural characteristics
- Highest flexural strength
- Highest stiffness-to-weight ratio
|
PC
(polycarbonate) | - Most widely used industrial thermoplastic with superior mechanical properties & heat resistance
- Accurate, durable and stable for strong parts, patterns for metal bending & composite work
- Great for demanding prototyping needs, tooling & fixtures
|
PC-ISO™
(polycarbonate – ISO 10993 USP Class VI biocompatible) | - Biocompatible (ISO 10993 USP Class VI)1 material
- Sterilize using gamma radiation or ethylene oxide (EtO) sterilization methods
- Best fit for applications requiring higher strength & sterilization
|
PC-ABS
(polycarbonate – acrylonitrile butadiene styrene) | - High dimensional stability & colorless transparency
- Five medical approvals including cytotoxicity, genotoxicity, delayed type hypersensitivity, irritation & USP plastic class VI
- Ideal for applications requiring prolonged skin contact of more than 30 days & short-term mucosal membrane contact of up to 24 hours
|
ASA
(acrylonitrile styrene acrylate) | - Build UV-stable parts with the best aesthetics of any FDM material
- Ideal for production parts for outdoor infrastructure & commercial use, outdoor functional prototyping, automotive parts & accessory prototypes
|
ABS-ESD7™
(acrylonitrile butadiene styrene – static dissipative) | - Static-dissipative with target surface resistance of 104 ohms (typical range 105 – 103 ohms)2
- Makes great assembly tools for electronic & static-sensitive products
- Widely used for functional prototypes of cases, enclosures & packaging
|
ABS-M30™
(acrylonitrile butadiene styrene) | - Versatile material: good for form, fit & functional applications
- Familiar production material for accurate prototyping
|
- 005 inch (0.127 mm) layer thickness not available for Stratasys F900.
- See individual material spec sheets for testing details.
- Annealed
- Actual surface resistance may range from 109 to 106 ohms, depending upon geometry, build style & finishing techniques.
- Available only on the Stratasys F370
For more material options, consult a Fathom specialist for details.
For additional flexible 3D printing options / / TPU 88A for SLS, PolyJet & Urethane Casting
Order Material Samples / / Keychains & Kits
FDM Parts In As Soon As Next Day / / Get A Quote
Selective Laser Sintering (SLS) Material
Selective Laser Sintering (SLS) technology is a commonly used powder-based additive technology to create models, prototypes and end-use parts in durable, engineering-grade thermoplastics. Consider SLS technology for applications that involve high-complexity and organic geometries, as well as parts requiring durability. SLS nests in the z direction which allows for short-run production and efficient builds. The technology is also capable of producing parts with finer details than most processes that use high-strength plastics. The composition is one of the more isotropic available from additive manufacturing.
How does SLS technology work?
SLS uses a blade to spread a thin layer of powder over the build volume. A laser sinters the cross-section of the part, fusing the powder together. The z stage then drops one layer and the process begins again until the build is finished. Parts are then excavated from the build powder-cake and bead blasted. The unused powder in the build envelope acts as the support structures, so no support removal is necessary.
SLS 3D Printed Parts and Images
SLS Material
Specifications
| SLS MATERIALS | LEAD TIME | OPTIMAL QUANTITY | MAXIMUM DIMENSIONS | SUGGESTED MINIMUM WALL THICKNESS | FINISH & APPEARANCE | ADVANTAGES & CONSIDERATIONS |
| TPU 88A | 2+ Days | Prototypes, Low-Volume, Short-Run Production | 320mm x 320mm x 610mm | 1mm | Standard Color: White
Medium/High Resolution
High Detail & Complexity
Dye Available (Black, Red, Blue, Green, Orange, Yellow and Pink) | High Elasticity, Rebound & Resistance to Fatigue
Water-Tight Down to 0.6mm Wall Thickness
High Burst Pressure
Excellent Flexibility & Durability |
| Nylon PA12 (White) | 2+ Days | Prototypes, Low-Volume, Short-Run Production | 320mm x 320mm x 610mm | 1mm | Standard Color: White
Medium/High Resolution
High Detail & Complexity
Dye Available (Black, Red, Blue, Green, Orange, Yellow and Pink) | Nearly Isotropic
Parts Built Without Supports, Allowing for Complex Geometries
Durable Production-Grade Thermoplastic |
| PA 12 Glass Bead | 3+ Days | Prototypes, Low-Volume, Short-Run Production | 320mm x 320mm x 610mm | 1mm | Standard Color: Off White
Medium/High Resolution
High Detail & Complexity
Dye Available** (Black, Red, Blue, Green, Orange, Yellow and Pink) | High Rigidity
Resistant To Wear & Tear
Thermally Resilient |
| PA 11 | 3+ Days | Prototypes, Low-Volume, Short-Run Production | 320mm x 320mm x 610mm | 1mm | Standard Color: White
Medium/High Resolution
High Detail & Complexity
Dye Available (Black, Red, Blue, Green, Orange, Yellow and Pink) | High Impact Resistance & Elongation At Break
Higher Temperature Resistance Than PA 12
Does Not Splinter Under Load |
| PA 11 Fire Retardant | 4+ Days | Prototypes, Low-Volume, Short-Run Production | 320mm x 320mm x 610mm | 1mm | Standard Color: White | High Ductility Combined With Strength
Flame-Retardant Properties Similar To ULTEM Filament |
| Carbon-Filled Nylon 11 | 4+ Days | Prototypes, Low-Volume, Short-Run Production | 320mm x 320mm x 610mm | 1mm | Standard Color: Dark Grey | High Strength Combined with Increased Impact Resistance & Elongation At Break
Electrostatically Dissipative |
*Geometry Dependent
**Filled Nylons Can Have Inconsistent Color When Dyed
For additional flexible 3D printing options // TPU 92A for FDM, PolyJet & Urethane Casting
Order Material Samples // Keychains & Kits
SLS Parts In As Soon As 2 Days // Get A Quote
MJF Material
Multi Jet Fusion (MJF) technology is quickly becoming a popular choice for 3D printing prototypes and production parts. Ideal uses for MJF are enclosures, electronics housings, complex ducts, lattice structures and functional assemblies. The technology is capable of 3D printing parts with high detail, as well as suitable for applications that require durability (e.g. snap fits). It is common for designers and engineers to choose this material for short production runs because the MJF process allows for nesting in the z direction. Offering this technology further expands Fathom’s already comprehensive 3D printing and additive manufacturing services. To learn more about MJF, read a featured FAQ blog post by a Fathom Applications Engineer.
How does MJF technology work? MJF builds parts by laying down a thin layer of powder on a print bed layer-by-layer. The inkjet array in the print carriage sweeps over the print bed, jetting two agents downward—a fusing agent, printed where the powder will fuse together and a detailing agent that is used to reduce fusing at the part boundary in order to achieve greater detail.
Nylon 12 is a commonly used thermoplastic that is strong enough for functional prototyping and production parts, small to medium in size—ideal for complex assemblies, housings, enclosures and watertight applications. Achieve smooth surfaces and fine details with this durable material. It provides excellent chemical resistance to oils, greases, aliphatic hydrocarbons and alkalies. Parts produced are a non-uniform light gray and can be dyed a darker color for a uniform appearance.
MJF Material
STANDARD
MJF MATERIAL | LEAD TIME | OPTIMAL
QUANTITY | MAXIMUM DIMENSIONS | SUGGESTED MINIMUM
WALL THICKNESS | FINISH
& APPEARANCE | ADVANTAGES
& CONSIDERATIONS |
| Nylon 12 (Gray or Dyed Black) | 2+ Days | Prototypes, Low-Volume, Short-Run Production | 274mm x 370mm x 360mm | 1mm | - Medium/High Resolution
- Very High Detail & Complexity
- Minimal Layer Visibility
- Paint, Plate, Metalize, Polish, Tumble
| - Nearly Isotropic
- Very High XY Plane Resolution
- Durable Production Quality Thermo
|
MJF Parts In As Soon As 2 Days // Get A Quote
Direct Metal Laser Sintering (DMLS) 3D Material
Metal 3D printing technology, also known as Direct Metal Laser Sintering (DMLS) and Direct Metal Laser Melting (DMLM) is a metal-based additive layer technology. Streamline your manufacturing with precision metal prototypes and low-volume metal production parts that would be impractical or cost prohibitive to machine. Fathom creates metal parts using a fiber laser fired onto a metal plate, repeatedly adding layers of powdered metal and fusing them to previous layers. Although the resulting part is accurate with excellent surface quality and mechanical properties, additional post-processing is recommended.
How does DMLS technology work? A metal 3D printer utilizes a laser beam to melt 20-60 micron layers of metal powder on top of each other. Powdered metal is spread across the entire build platform and selectively melted to previous layers. This additive process allows metal parts to be grown out of a bed of powdered metal. The process is like other polymer-based 3D printers that use powder bed fusion.
Benefits of Metal Prototypes / /
- Precision
- High-Quality
- Low-Volume
- Strength
In-House Post-Processing / /
- Support Removal
- CNC Secondary Machining (Critical Dimension & Re-Qualification)
- Tapping, Threading and Helicoils
- Vibratory Polishing & Surface Treatment
- Annealing & Age Hardening
- Painting & Finishing
Fathom uses EOS & SLM build platforms.
- The build volume for the SLM is 11 x 11 x 13.8 inches
- The build volume for the EOS is 9.85 x 9.85 x 8.5 inches
Materials include / /
- Stainless Steel
- Maraging Steel
- Inconel
- Aluminum
- Titanium
- Other Materials Available On Demand
DMLS 3D Printing Materials & Specifications
| Material | Alloy Designation | Layers | Hardness | Advantages | Applications |
| Stainless Steel (PH1) | 15-5 PH, DIN 1.4540 & UNS S15500 | 20 or 40 Micron Layers | 30-35 HRC Built, Post Hardened to 40 HRC | High Hardness & Strength | Prototype & Production Parts |
| Stainless Steel (GP1) | 17-4, European 1.4542, German X5CrNiCuNb16-4 | 20 or 40 Micron Layers | 230 ± 20 HV1 Built, Ground & Polished to 250-400 HV1 | High Toughness & Ductility | Engineering Applications |
| Cobalt Chrome (MP1) | ISO 5832-4 & ASTM F75 | 20, 40 or 50 Micron Layers | 35-45 HRC Built | High Temperature Resistance | Turbines & Engine Parts |
| Maraging Steel (MS1) | 18% Ni Maraging 300, European 1.2709, German X3NiCoMoTi 18-9-5 | 20 or 40 Micron Layers | 33-37 HRC Built, Post Hardened to 50-56 HRC | Easily Machinable & Excellent Polishability | Injection Molding, Tooling, Conformal Cooling |
| Aluminium AlSi10Mg | Typical Casting Alloy | 30 Micron Layers | Approx 119 ± 5 HBW | Low Weight, Good Thermal Properties | Automotive, Racing |
| NickelAlloy IN718 | UNS N07718, AMS 5662, AMS 5664, W.Nr 2.4668, DIN NiCr19Fe19NbMo3 | 40 Micron Layers | 30 HRC Built, Post Hardened 47 HRC | Heat & Corrosion Resistant | Turbines, Rockets, Aerospace |
| Stainless Steel (316L) | ASTM F138 | 20 Micron Layers | 85 HRB | Corrosion & Pitting Resistant | Surgical Tools, Food & Chemical Plants |
| Titanium Ti-64* | ASTM F2924 | 30 or 60 Micron Layers | 320 ± 15 HV5 | Lightweight, High Strength, Corrosion Resistance | Aerospace, Motorsport Racing |
| Titanium Ti-64 ELI* | ASTM F136 Properties | 30 or 60 Micron Layers | 320 ± 15 HV5 | Corrosion Resistance, Biocompatibility | Medical, Biomedical, Implants |
*Please contact an Expert@Fathommfg.com for more information
DMLS Parts In As Soon As 3 Days / / Get A Quote
3D Printing Material Finishes
A part made using additive manufacturing can have the same look, feel and finish as a product made using traditional manufacturing. Any finishing that may be required depends on the kind of additive manufacturing method used. Finishing may include / /
- Support Removal / / This may include the use of a water jet, removing the support by hand, a chemical bath or digging. Support removal varies by the technology used.
- Sanding / / Once the support is removed, the part may be sanded by hand or sanded using a machine. Sanding is necessary if there are any traces of the support structures.
- Mass finishing / / The parts are placed inside a tub filled with sanding/polishing media. The parts are tumbled inside the tub and the movement works to remove imperfections from the surface of the part. This method is not suitable for objects with delicate features. Mass finishing may be used if sanding by hand is too time-consuming.
- Painting / / Parts may be dyed or painted. Some parts may be sprayed with a specialty paint that gives the object a different texture. Painting is necessary when a designer would like to change the color or texture of a part.
- Electroplating / / The part is immersed in a solution of water and metal salts. An electrical current is passed through it, which allows metalcations to form around the part. If a thicker layer is desired, several layers may be applied. Electroplating increases the strength of the part by adding an exoskeleton. The electroplating process may be used to give an object the look of higher quality material.
- Bonding / / Bonding may include solvent bonding, super gluing, epoxies, hot air welding or ultrasonic spot welding. Bonding is necessary when a part is printed in small pieces that must be assembled to form a larger product.
- Infiltration / / Infiltration uses an epoxy resin which is brushed onto the part’s surface. The resin sinks into the pores within the material. The part is then cured inside an oven. Infiltration adds strength, water tightness and chemical resistance to an object and may be used if a 3D printed part is fragile.
- Bead blasting / / Plastic or glass beads are sprayed over a part using a blaster gun, giving the part a uniform matte finish. This is particularly useful for parts made using SLS as it removes any unsintered powder that may be stuck to the surface. Bead blasting preps the part for painting.
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