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Thermoplastic Polyurethanes (TPU) are a category of materials that feature rubber-like mechanical properties. Parts made from TPU tend to stretch and flex easily while maintaining their original shape. This unique property of TPU enables it to fulfill a variety of applications that require flexibility. Though flexible, TPU is a tough material. It features a hardness that is comparable to PETG depending on the specific TPU used. This makes it as useful in harsher industrial applications as it is in gentler environments. When flexibility is key, TPU is the best material for the job.

TPU’s flexibility is the driver for most of its applications. This flexibility comes into great use in footwear where a cushion is needed for a shoe’s sole. Wheels and tires are another example where TPU’s flexibility shines. TPU is a good choice for phone cases and handles by providing a softer grip and a dampening effect. In industrial uses, TPU excels for grommets and dampers where traditional rubber is too weak. TPU’s hardness and flexibility enable dampers and grommets to endure for a long time.

TPU recycling does exist, but the ability to recycle 3D printed TPU parts remains uninvestigated. Usually TPU recycling involves breaking down a specific TPU product and reusing its material in the same application it came from. For example, polyurethane foam from mattresses tends to be recycled into new mattresses.

ABS

Acrylonitrile Butadiene Styrene (ABS) is another common 3D printing material with popularity that rivals PLA. ABS’s structure contains a long chain on butadiene that crosses with shorter chains of acrylonitrile and styrene. The proportions of each monomer in ABS can vary. ABS is resistant to heat and to impact damage making it a durable material suitable for the outdoors. Its mechanical and thermal properties also give parts a cleaner finish compared to PLA. Due to its chemical nature, printing with ABS usually requires a raft in order to guarantee bed adhesion. This makes it a suitable material for those who have some experience with 3D printing already.

ABS’s durability and temperature resistance allow it to endure life outside. This makes it a good material for enclosures outside. ABS also serves as a good material for custom pipes that may operate outside. ABS’s durability and price point enable it to serve as a suitable material for handles on devices such as power tools. ABS can also replace automotive trim and endure usage on a car. ABS is also the material used in LEGOs. For those wanting to replicate or create new LEGOs, ABS is a perfect material.

Nylon

Nylon is a range of materials that are often used for industrial engineering applications. Its chemical nature allows it to mix with additives that change its behavior for certain applications. This is easily seen with the variety of nylon filaments that exist. Most nylon filaments share some common features. They are usually resistant to high temperatures and wear. They also have decent strength characteristics that let it excel in industry. Nylons vary in their flexibility and their strength depending on the resin and application. For parts that find themselves in cars, equipment, and industry, nylon gets the job done.

Nylon, especially the stiffer variety, is perfect when creating mounts for car parts. Its durability and tolerance to heat make it right at home inside an engine bay. In industry, nylon is good for gears that need to have high durability and long life cycles. Two surprising areas of application are in shoes and prosthetics. Both application areas require durability and some flexibility. More flexible nylons are the perfect choice for these applications.

Nylon is recyclable, though its feasibility depends on the specific nylon resin. Nylon is not recycled at commercial recycling centers since it tends to be variable as well. Efforts to recycle nylon products such as fishing nets into filament have proven successful. Though recyclable, nylon needs to be considered on a case-by-case basis.

PET

Polyethylene Terephthalate (PET) is a durable material with a glossy appearance. Outside of PLA and ABS, PET is a very common filament. A variation of PET, PETG, is often sold as a filament as well. PETG is a form of Polyethylene Terephthalate (PET) with glycol introduced. The introduction of glycol causes PET to become more flexible and resistant to impacts. PETG also resists shrinking and sticks to other materials easily, unlike other materials that print at a similar nozzle temperature to PETG. These properties allow PETG to fill a role between PLA and ABS as a strong, easy to print material. PETG is used for water bottles, oil containers, and plastic packaging. Recycled versions of PET and PETG, often called rPET, is a go-to recycled material for many closed loop applications. For those looking to branch from PLA and create more durable parts, PET, PETG, and rPET are good choices.

PETG excels when you take advantage of its material properties. If you need something that can endure the outdoors, PETG’s impact strength makes it a suitable material. Its chemical makeup makes it bond easily to other materials and serve as a versatile support material.

PET is one of the most commonly recycled materials. Reground PET is often turned into rPET filament for 3D printing. PETG is technically recyclable, but it is often rejected from commercial recycling centers due to its low melting point causing issues when recycled with other materials. It may be possible to regrind PETG and to reuse it in pellet fed printers such as GBX.

PLA

Polylactic Acid, more commonly known as PLA, is one of the most frequently used materials in 3D printing. Its popularity comes from its ease of use, organic nature, and relatively strong mechanical properties. PLA is also inexpensive making it a great entry-level material. PLA is made up of naturally occurring, organic lactic acid chains which generally makes it useful in organic settings such as medical applications. Its chemical nature also makes it easy to recycle and reuse. PLA also boasts strong mechanical properties and user-friendly thermal properties that make it easy to print with. For those looking for a place to start in additive manufacturing, PLA is an excellent choice.

PLA is a great material for applications that require rapid prototyping and strong parts. Its ease of use and low cost make it suitable when a part may be frequently reprinted as is the case in prototyping and architecture. For those who are still learning to 3D print, or for those who are teaching others, PLA is a great introduction to 3D printing. The thermal properties of PLA also make it useful as an alternative to lost wax casting where the PLA is burned away instead of a wax.

PLA is created from organic sources, making it sustainable to produce. It is possible to recycle through composting. Furthermore, PLA is easily reused if ground up and reused in pellet printers such as GBX. PLA can only be reused a limited amount of times due to its compostable nature. PLA is not easily recycled at commercial recycling centers due to it being lumped into code 7, “other plastics”, in the resin identification number system.