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Table of Contents

Plastic 3D Printing Capabilities

Fused Deposition Modeling (FDM):

Fused Deposition Modeling (FDM) is a widely used 3D printing method ideal for creating durable plastic parts with complex geometries. It works by extruding thermoplastic filaments layer by layer, allowing for rapid prototyping and the production of end-use parts with a variety of materials, including ABS, PLA, and Nylon.

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Stereolithography (SLA):

Stereolithography (SLA) is a precision 3D printing technology that uses a laser to cure liquid resin into solid parts. This process is perfect for creating high-detail prototypes with smooth surface finishes, making it suitable for intricate plastic components used in industries such as medical devices and consumer electronics.

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Selective Laser Sintering (SLS):

Selective Laser Sintering (SLS) is an advanced 3D printing technique that fuses powdered thermoplastic materials layer by layer using a laser. It’s ideal for producing durable, functional plastic parts without the need for support structures, which makes it perfect for creating complex designs and small to medium production runs.

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Multi Jet Fusion (MJF):

Multi Jet Fusion (MJF) is a cutting-edge 3D printing technology that builds parts by fusing nylon powder layer by layer using a detailing agent and a fusing agent. MJF excels in producing high-strength, isotropic plastic parts with excellent surface quality and dimensional accuracy, suitable for functional prototypes and end-use applications.

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Plastic 3D printing is frequently employed for:

  • Developing prototypes with engineering-grade plastics

  • Fabricating parts with complex geometries

  • Producing durable components ready for end-use

  • Reducing the number of plastic parts in an assembly

Plastic 3D Printing Handbook

Begin your plastic 3D printing journey with this comprehensive guide, covering material selection, design best practices, post-processing methods, and quality inspection procedures.
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Fused Deposition Modeling (FDM) - Precision and Tolerances

ParameterPrecision/Tolerance
Dimensional Accuracy±0.15mm to ±0.3mm (depending on geometry and size)
Layer Thickness100 to 300 microns
Surface Roughness (As-Built)Ra 10-30 microns
Minimum Feature SizeTypically 0.5mm (depending on material)
Wall ThicknessMinimum 0.8-1.2mm (depending on material and part geometry)
Positional Tolerance±0.1mm to ±0.3mm
Hole DiameterMinimum 1mm (depending on geometry)
Part Density~95% (depending on material)
Build SizeUp to 914 x 610 x 914 mm (standard)

Stereolithography (SLA) - Precision and Tolerances

ParameterPrecision/Tolerance
Dimensional Accuracy±0.05mm to ±0.15mm (depending on geometry and size)
Layer Thickness25 to 100 microns
Surface Roughness (As-Built)Ra 1-5 microns
Minimum Feature SizeTypically 0.1mm (depending on material)
Wall ThicknessMinimum 0.6-0.8mm (depending on material and part geometry)
Positional Tolerance±0.05mm to ±0.15mm
Hole DiameterMinimum 0.2mm (depending on geometry)
Part Density~100% (depending on material)
Build SizeUp to 1500 x 750 x 500 mm (standard)

Selective Laser Sintering (SLS) - Precision and Tolerances

ParameterPrecision/Tolerance
Dimensional Accuracy±0.1mm to ±0.3mm (depending on geometry and size)
Layer Thickness80 to 150 microns
Surface Roughness (As-Built)Ra 6-12 microns
Minimum Feature SizeTypically 0.2mm (depending on material)
Wall ThicknessMinimum 0.8-1.0mm (depending on material and part geometry)
Positional Tolerance±0.1mm to ±0.3mm
Hole DiameterMinimum 0.6mm (depending on geometry)
Part Density~95% (depending on material)
Build SizeUp to 700 x 380 x 580 mm (standard)
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Comparison Table for Various 3D Printing Plastic Materials

3D Printing Plastic Materials

Here’s a table comparing the key material properties of various 3D printing materials:

MaterialStrength & DurabilityThermal PerformanceChemical PerformanceProcessabilitySurface QualityToughness & FlexibilityDensity & WeightOptical PropertiesWeather ResistanceBiocompatibility
ABS (Acrylonitrile Butadiene Styrene)Good mechanical strength, impact-resistantModerate heat resistance (Tg ~105°C)Moderate chemical resistance, not UV-resistantEasy to print, but prone to warpingGood, but often requires post-processingTough, low flexibilityMedium densityOpaque, available in various colorsPoor UV resistance, not suitable for outdoor useNot biocompatible
Photopolymer ResinVaries by resin type, generally brittleLow to moderate heat resistance (Tg ~50-70°C)Limited chemical resistance, sensitive to UVHigh precision, good for detailed partsSmooth surface qualityBrittle, low toughnessMedium to high densityTypically opaque or translucentPoor UV resistanceNot biocompatible, unless specifically formulated
TPU (Thermoplastic Polyurethane)Flexible, good impact resistanceModerate heat resistance (Tg ~80-100°C)Good chemical resistance, especially oils and greasesFlexible, good layer adhesion, but can be difficult to printSmooth surface with good detailHighly flexible and toughMedium densityOpaque or translucentGood UV resistanceNot typically biocompatible
PETG (Polyethylene Terephthalate Glycol)Strong and durable, good impact resistanceModerate heat resistance (Tg ~80°C)Good chemical resistance, including acids and basesEasy to print, minimal warpingGood surface finish, glossyTough with moderate flexibilityMedium densityTransparent or opaque, glossyModerate UV resistanceNot biocompatible
PLA (Polylactic Acid)Moderate strength, brittle under stressLow heat resistance (Tg ~60°C)Poor chemical resistance, biodegradableVery easy to print, low warpingGood, smooth finishLow toughness, brittleLow density, lightweightSemi-transparent or opaquePoor UV resistance, degrades outdoorsBiocompatible (food-safe versions available)
PEEK (Polyether Ether Ketone)Exceptional strength and durabilityExcellent heat resistance (Tg ~143°C)Excellent chemical resistance, including solventsDifficult to print, requires high temperaturesGood, but often requires post-processingVery tough, low flexibilityHigh density, heavy materialOpaqueExcellent weather resistanceBiocompatible, used in medical implants
Polycarbonate (PC)High strength, impact-resistantHigh heat resistance (Tg ~150°C)Good chemical resistance, especially against oilsChallenging to print, prone to warpingClear and transparent, good surface finishTough with low flexibilityMedium densityTransparentPoor UV resistance, yellows over timeLimited biocompatibility
ASA (Acrylonitrile Styrene Acrylate)Good mechanical strength, similar to ABSModerate heat resistance (Tg ~105°C)Good chemical resistance, better UV resistanceEasy to print, less warping than ABSGood surface finishTough, low flexibilityMedium densityOpaque, available in various colorsExcellent UV resistance, suitable for outdoor useNot biocompatible
Tough ResinHigh impact resistance, similar to ABSLow to moderate heat resistance (Tg ~50-70°C)Limited chemical resistanceHigh precision, good for functional prototypesSmooth surface qualityTough with moderate flexibilityMedium to high densityOpaque, some translucencyPoor UV resistanceNot biocompatible, unless specifically formulated
Flexible ResinFlexible with rubber-like propertiesLow heat resistance (Tg ~50°C)Limited chemical resistanceHigh precision, more difficult to printSmooth, flexible surfaceHighly flexibleMedium densityOpaque or translucentPoor UV resistanceNot biocompatible, unless specifically formulated

This table covers a broad range of materials used in 3D printing, highlighting their key properties that are of interest to mechanical designers and procurement professionals.

Surface Finish Options

Selective Laser Sintering (SLS) part
Surface FinishDescription
Standard (Uncoated)Remove loose powder and bead blast.
Standard (Coated)Remove loose powder, bead blast, apply sealant.
As PrintedTypically white or stone gray, smooth surface, powder texture, without visible layers.
Color DyedDye options include black, blue, green, red, or yellow. Dye penetrates approximately 0.010″ deep.
Vapor SmoothingBrings most surfaces from matte to semi-gloss, seals the surface, enhances mechanical properties, and provides a consistent cosmetic finish for production.
Media TumbledReduces grow lines and softens sharp edges. Leaves parts with an eggshell finish.
Paint-ReadyStandard finish plus removal of build/layer lines on visual surfaces, followed by multiple stages of priming and sanding.
PaintedPaint-ready finish with a specified paint color applied.
ElectroplatingImproves strength and adds a metal-like surface texture.
PolishedPolishes the surface to improve transparency and light transmittance for transparent parts.
Spray PaintingProvides painted finishes in matte, high-gloss, varnish, and other effects according to the customer’s specifications.
Nickel PlatingAdds 0.004″-0.006″ of nickel coating, enhancing durability and wear resistance.

These options are ideal for improving both the aesthetic and mechanical properties of 3D-printed parts​​​​.

Selective Laser Melting (SLM) 3D Printing (1)

How Does Plastic 3D Printing Work?

Imagine building a house layer by layer, but instead of bricks, you use thin layers of plastic or resin. In plastic/resin 3D printing, a digital blueprint guides the process. The printer lays down material, one layer at a time, just like stacking paper-thin sheets until the final shape emerges. Each layer bonds to the one below, creating a solid object. It’s like icing a cake, where each layer of icing adds to the overall structure, eventually forming the desired shape.

Advantages of 3D Printing Plastic Parts Compared to CNC Machining

Complex Geometry

3D printing excels at creating intricate designs that would be difficult or impossible to achieve with CNC machining, allowing for more creative freedom in product development.

Material Efficiency

Unlike CNC machining, which often involves cutting away material, 3D printing builds parts layer by layer, minimizing waste and reducing material costs.

Customization

3D printing allows for easy customization of parts, enabling the production of unique or specialized components without the need for additional programming or tooling changes.

Lightweight Structures

3D printing can create lightweight structures with complex internal geometries, such as lattice structures, that are difficult to achieve with traditional machining methods.

Limitations of 3D Printing Plastic/Resin Parts Compared to CNC

Material Strength

3D-printed plastic and resin parts typically have lower mechanical strength and durability compared to parts machined from solid blocks of material, limiting their use in high-stress applications.

Surface Finish

CNC machining generally provides a superior surface finish and tighter tolerances compared to 3D printing, which may require additional post-processing to achieve a smooth, polished appearance.

Limited Material Options

While 3D printing offers various plastics and resins, CNC machining supports a broader range of materials, including high-performance plastics and metals, providing greater versatility.

Size Constraints

3D printers have size limitations, restricting the dimensions of parts that can be produced in a single run. CNC machining can handle larger and more complex parts without this constraint.

Layer Bonding Weakness

In 3D printing, parts are built layer by layer, which can result in weak points along the layer lines. CNC machined parts, carved from a solid block, don't have this issue and can be more robust.

Post-Processing Requirements

3D-printed parts often require additional post-processing steps, such as sanding, polishing, or support removal, which can add time and cost to the production process compared to CNC machining, where the finished part is often ready for use immediately.

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Pricing Structure for Plastic/Resin 3D Printing Components

Material Pricing
The cost of plastic and resin materials can vary significantly based on the type and quality of the material. Common plastics like ABS or PLA may range from $20 to $50 per kilogram, while specialized resins can be higher, depending on the supplier and market conditions.

Design Complexity
Complex designs with intricate details, overhangs, or tight tolerances may require additional supports and more precise printing, which can increase costs due to extended printing time and additional post-processing requirements.

Printing Duration
The printing time for plastic and resin parts directly impacts the cost. More complex or larger parts will require longer build times, which increases the overall price. Techniques such as SLA (Stereolithography) or SLS (Selective Laser Sintering) can also affect the cost depending on the speed and resolution of the print.

Post-Processing Techniques
Optional finishing processes, such as sanding, painting, and curing (for resin prints), can add to the total cost. These steps are essential for achieving the desired surface quality and functional properties.

Support Material and Removal
Plastic and resin parts often require supports during printing, which need to be carefully removed in post-processing. This process incurs additional labor costs, particularly for complex or detailed parts.

Consider a typical plastic or resin component with the following specifications:

  • Size: 100mm x 50mm x 10mm
  • Design Complexity: Moderate
  • Surface Treatment: Sanded and Painted
  • Order Volume: 100 units

Material Pricing

  • Cost of plastic or resin material per kilogram: $30
  • Volume per unit: 0.2 kilograms
  • Total material price: 100 units x 0.2 kilograms/unit x $30/kilogram = $600

Printing Pricing

  • Time required for printing moderate complexity: 2 hours per unit
  • Rate per printing hour: $40/hour
  • Total printing price: 100 units x 2 hours/unit x $40/hour = $8,000

Post-Processing Cost

  • Cost for sanding and painting: $20 per unit
  • Total post-processing price: 100 units x $20/unit = $2,000

Support Removal

  • Estimated labor cost for support removal: $10 per unit
  • Total support removal price: 100 units x $10/unit = $1,000

Additional Expenses

  • Charges for quality assurance and inspection: $300
  • Costs for packaging and delivery: $200

Total price = Material price + Printing price + Post-processing cost + Support removal + Additional expenses
Total price = $600 + $8,000 + $2,000 + $1,000 + $500 = $12,100

Price per unit = Total price / Order volume
Price per unit = $12,100 / 100 units = $121/unit

This example provides a general idea of the costs involved in 3D printing plastic or resin components. Prices may vary based on specific design requirements, processing techniques, and order volumes. For an accurate quote, detailed mechanical drawings and technical specifications should be provided. We will then offer a customized quote tailored to your specific needs.

Bulk Order Incentives and Base Order Requirements

Modo Rapid offers discounts for bulk orders, making larger quantities more cost-effective. We accommodate both small and large projects with flexible base order requirements.

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Production Capacity and Delivery Time

Estimated Delivery Timeframe

At Modo Rapid, we prioritize delivering your orders promptly while ensuring the highest quality standards. Typically, you can expect your order to be delivered within 3 to 7 days, which includes:

  • Order Review and Setup: 1-2 days
  • Material Acquisition: 1-2 days
  • Manufacturing and Machining: 2-3 days
  • Quality Assurance: 1 day
  • Packaging and Dispatch: 1 day

Accommodating Urgent Orders

We understand that some projects require a faster turnaround. If you need your order expedited, please inform us when placing the order. We offer rush processing, though additional costs may apply depending on our workload and the complexity of your project. In many cases, we can adjust our schedule to deliver your order within as little as 3 days.

Our team is committed to meeting your deadlines, even for high-priority tasks. For more details on rush processing or to discuss your specific needs, please reach out to us directly. We are here to work with you to ensure your project stays on track.

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Quality Control and Quality Consistency in 3D Printing

Our Quality Assurance Practices:

Precision Measurement Tools: We use state-of-the-art CMMs (Coordinate Measuring Machines), laser scanners, and precision gauges to ensure every dimension and geometry is accurately captured.

Real-Time Production Monitoring: Our vigilant monitoring during the machining process allows us to immediately identify and correct any deviations, ensuring consistent quality throughout.

Rigorous Material Testing: We conduct exhaustive tests on all materials for chemical composition and mechanical properties, ensuring they meet your precise specifications.

Surface Quality Verification: By employing advanced profilometers and other tools, we make certain that every part adheres to the highest surface quality standards you expect.

Controlled Manufacturing Environment: We maintain strict environmental conditions to reduce any impact of temperature and humidity fluctuations on the precision of our machining.

 

Strategies for Consistent Quality Across Batches:

Standardized Operational Protocols: Each operation follows rigorously defined procedures, promoting uniformity and repeatability across all production runs.

Initial Batch Inspection: We conduct comprehensive first article inspections to confirm that the initial product of each batch meets your requirements before commencing full-scale production.

Statistical Quality Control: We apply statistical process control methods to ensure that our manufacturing processes remain within your required precision limits.

Batch Traceability: Our detailed traceability systems track every material and process step for each batch, enhancing our ability to quickly pinpoint and address any quality concerns.

Thorough Final Assessments and Tests: Before any part leaves our facility, it undergoes a stringent final inspection and functional testing to ensure it meets your exact specifications and quality expectations.

With these rigorous quality control protocols in place, we are dedicated to delivering consistently high-quality parts that support the success and dependability of your projects.

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Maximum and Minimum 3D Printing Part Sizes

Maximum 3D Printed Part Size

3D Printing TechnologyMachine/Printer ModelMaximum Part Size (L x W x H)Minimum Part Size
Fused Deposition Modeling (FDM)Creality Ender 3220 x 220 x 250 mm~10 x 10 x 1 mm
Fused Deposition Modeling (FDM)Prusa i3 MK3S250 x 210 x 210 mm~10 x 10 x 1 mm
Fused Deposition Modeling (FDM)Ultimaker S5330 x 240 x 300 mm~10 x 10 x 1 mm
Stereolithography (SLA)Formlabs Form 3145 x 145 x 185 mm~1 x 1 x 1 mm
Stereolithography (SLA)Anycubic Photon Mono X192 x 120 x 245 mm~1 x 1 x 1 mm
Digital Light Processing (DLP)EnvisionTEC Perfactory Mini80 x 80 x 80 mm~1 x 1 x 1 mm
Digital Light Processing (DLP)MoonRay S127 x 80 x 160 mm~1 x 1 x 1 mm
Selective Laser Sintering (SLS)EOS Formiga P110200 x 250 x 330 mm~10 x 10 x 10 mm
Selective Laser Sintering (SLS)3D Systems ProX SLS 6100381 x 330 x 457 mm~10 x 10 x 10 mm

The sizes mentioned are approximate and can vary depending on specific models and manufacturers. Always check the specifications of the specific machine you’re interested in for precise dimensions.

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Minimum 3D Printed Part Size

 

3D Printing TechnologyMinimum Part Size
Fused Deposition Modeling (FDM)~0.1 mm (depends on nozzle size and layer height)
Stereolithography (SLA)~0.025 mm (fine details possible)
Digital Light Processing (DLP)~0.1 mm (similar to SLA)
Selective Laser Sintering (SLS)~0.5 mm (depending on powder size and laser resolution)
Material Jetting (PolyJet)~0.016 mm (very high resolution)
Multi Jet Fusion (MJF)~0.5 mm (varies with part geometry and build parameters)
Electron Beam Melting (EBM)~0.1 mm (for finer details)

 

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Most Popular Questions

PLA is biodegradable and made from renewable resources like corn starch. However, other materials like ABS and PET are not biodegradable, with ABS being derived from petroleum. For eco-conscious buyers, PLA and recycled PET options may be more attractive.

ABS and PLA are widely available and cost-effective, making them popular for both industrial and hobbyist applications. ABS offers durability, while PLA is easier to print and doesn't require a heated bed.

ABS and ASA are strong and impact-resistant, with ASA offering better UV resistance. For high-performance needs, materials like PEEK, PEKK, and ULTEM provide excellent mechanical and thermal properties, making them suitable for aerospace and automotive applications.

PET is suitable for food contact applications due to its semi-rigid nature and resistance, while ASA is ideal for outdoor use due to its UV resistance. For industrial applications requiring high mechanical properties, PEEK or ULTEM are recommended.

PLA and ABS are compatible with most FDM 3D printers. More advanced materials like PEEK, PEKK, and polycarbonate require specialized printers with higher temperature capabilities and enclosed chambers.

ABS provides a polished surface and can be chemically smoothed. Hybrid materials, like those mixed with wood or metal powders, offer unique colors and textures. For transparent parts, polycarbonate is a good option.

Flexible materials like TPE and TPU are ideal for creating malleable parts. They provide flexibility while maintaining the ease of use similar to PLA.

HP offers a range of thermoplastic materials designed specifically for HP Multi Jet Fusion technology. These materials emphasize functional part creation, optimizing cost and part quality, and providing high reusability, such as HP 3D High Reusability Polypropylene (PP), which allows up to 100% surplus powder reuse.

HP’s thermoplastic materials, like Polypropylene (PP), offer high reusability. This not only reduces material costs but also minimizes waste, improving overall cost efficiency.

Composites/Fiber Reinforced Materials (FRM) are ideal for producing lightweight but strong parts. Common reinforcing fibers include carbon fiber, glass fiber, and Kevlar, which can be mixed with thermoplastics such as nylon, ABS, or PLA.

Polylactic Acid (PLA) is a biodegradable material suitable for making food packaging and biodegradable medical devices. It is made from renewable raw materials like corn starch, making it more environmentally friendly.

Acrylic Styrene Acrylonitrile (ASA) is known for its UV resistance, making it suitable for outdoor applications. It also offers good temperature and impact resistance.

For printing tasks requiring dissolvable support structures, HIPS and PVA are common soluble materials. HIPS can be used with ABS and dissolved with limonene, while PVA can be used with PLA and dissolved with water.

High-performance polymers (such as PEEK, PEKK, and ULTEM) offer mechanical and thermal properties comparable to metals and are ideal for aerospace, automotive, and medical applications.

Polycarbonate (PC) is prone to absorbing moisture from the environment, which can significantly affect its performance and durability. Therefore, PC should be stored in airtight containers.

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Why Choose Us

Precision

Our metal 3D printing services achieve exceptional precision, meeting strict tolerances for even the most complex designs. With advanced technologies like DMLS and SLM, we deliver parts with outstanding detail and accuracy, ensuring your components fit and function perfectly.

Fast Turnaround

With production times ranging from 1-7 days, Modo Rapid quickly delivers high-quality 3D printed parts, allowing you to meet tight project deadlines without sacrificing quality.

24/7 Operations

Our 24/7 operations ensure continuous production and on-time delivery, no matter how tight the deadline. We’re always ready to meet your urgent 3D printing needs.

Seamless Communication

At Modo Rapid, we prioritize effective communication. Our team is readily available via video calls, phone calls, and emails, making collaboration smooth and efficient throughout the 3D printing process.

Consistent Finishing

Our post-processing services, including polishing, bead blasting, and anodizing, deliver consistent, high-quality finishes. We ensure your 3D printed parts are not only functional but also visually appealing.

VIP Shipping Rates

Thanks to our VIP partnerships with leading shipping companies, Modo Rapid offers reduced shipping costs, ensuring your 3D printed parts arrive quickly and affordably, no matter where you are located.

What they say about us

I had very strict dimensional requirements for my part, and Modo Rapid delivered flawlessly. The 3D printed metal part featured clean, precise threading and a finely detailed surface finish. I’m thoroughly impressed with the accuracy and aesthetics.
Harrison Atkinson
Harrison Atkinsontechnical buyer
The stainless steel component I ordered turned out exactly as needed. The surface is smooth and glossy, and the threads are incredibly clean. Modo Rapid nailed every detail. I’ll definitely be returning for future 3D printing projects.
Customer Testimonials
Bethany RogersEngineer
I was concerned that some of the intricate shapes on my part wouldn’t be possible with 3D printing. But when I received the final piece, I was blown away. Every dimension, shape, and thread was executed perfectly. The bead-blasted and anodized finish looks fantastic. Despite being a one-off, the part looks professional and fits perfectly into my assembly.
Samuel Wood
Samuel WoodProject Manager
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