The success of any rapid prototyping project hinges on a multitude of factors, but the selection of the appropriate material often stands as the cornerstone. Rapid prototyping, a collection of techniques designed to quickly fabricate a physical part or assembly using three-dimensional computer-aided design (CAD) data, has become an indispensable tool for accelerating product development cycles.
The chosen material dictates not only the prototype’s aesthetic appeal but also its functional capabilities, durability, and its ability to accurately represent the characteristics of the final product. This guide serves as a comprehensive resource for understanding the diverse landscape of common rapid prototyping materials, exploring their key properties, compatible processes, and typical applications across various industries.
Common Rapid Prototyping Materials
Understanding the specific properties of various materials is essential for selecting the optimal choice for a given prototyping project. The following sections detail some of the most common materials used in rapid prototyping, categorized for clarity.
Plastics
Plastics are versatile and widely used in rapid prototyping, offering a range of properties from strength and rigidity to flexibility and biodegradability.
| Material | Key Properties | Compatible Processes | Typical Applications |
| ABS | Strong, impact-resistant, affordable, rigid, weldable, good electrical insulation, high abrasion/strain quality, good dimensional stability | FDM 3D printingCNC machining, injection molding | Functional prototypes, concept models, automotive parts (concept cars, engine components), consumer electronics (casings), healthcare devices, toys, mechanical parts |
| PLA | Biodegradable, smooth finish, good strength, high stiffness, low melting point, good aesthetics, dimensionally stable, affordable | FDM 3D printing | Visual prototypes, concept models, low-stress applications, architectural mockups, aesthetic models, casting molds, packaging, medical, food, cosmetics, textiles |
| PETG | Durable, chemical resistant, temperature resistant (better than PLA/ABS), high strength, dimensionally stable, clear, impact resistant | FDM 3D printing, CNC machining, thermoforming | Functional prototypes, jigs, fixtures, end-use parts, liquid containers, signage, electrical enclosures, manufacturing tooling, automotive, packaging, engineering, medical devices, machine guards |
| Nylon (PA) | Durable, wear-resistant, flexible, high strength, tough, high mechanical properties, chemical resistant, high melting point | SLS & FDM 3D printing, CNC machining, injection molding | Flexible/strong parts, tools, mechanical parts, functional prototypes, complex thin-walled pipes, shells, impellers, connectors, consumer sports goods, dashboards, gears, outdoor gear, biomedical |
| PC | Robust, durable, high impact strength, dimensionally stable, temperature resistant, high flexural/tensile strength, flame-retardant, clear | FDM 3D printing, CNC machining, injection molding | Functional prototypes, end-use parts (demanding engineering), optical tech, automotive (lenses), consumer products (lenses), medical products (custom structures), CDs, DVDs |
| TPE / TPU | Rubber-like, durable, elastic, wear/tear resistant, bendable, high tensile/tear strength, chemical resistant, wide hardness range | FDM & MJF 3D printing, CNC machining, injection molding, extrusion, blow molding | Prototypes needing wear/bending/stretching (toys, wearables, shoes, sports gear, phone cases), seals, gaskets, hoses, caster wheels, grips, drive belts, automotive parts |
| Acrylic (PMMA) | Transparent, high optical clarity, weather/scratch resistant, strong, stiff, easy to fabricate/machine/thermoform, bonds well | CNC machining, 3D printing, vacuum casting, thermoforming, injection molding | Glass mimics (windows, walls, pools), lenses, light parts, signs, displays, architectural elements, sanitary fixtures, medical devices, consumer products |
| HIPS | Affordable, easily milled/fabricated, good impact resistance, dimensionally stable, easy to paint/glue, good aesthetics, lightweight | CNC machining, extrusion, injection molding, thermoforming | Low-strength structural applications, machined prototypes, covers, housings, packaging, diagnostic trays, sample cups, consumer goods |
| PP | Lightweight, durable, chemical resistant, flexible, high tensile/impact strength, heat/electrical/fatigue resistant, low density | SLS, FDM, MJF 3D printing, injection molding, extrusion, blow molding | Durability/low weight apps (packaging, textiles, banknotes), complex shapes, pipes, shells, impellers, connectors, snap-fits, living hinges, automotive, medical, industrial tanks |
Resins
Resins, often cured by light or chemical reaction, are chosen for their ability to produce prototypes with fine details, smooth finishes, and varying degrees of hardness and flexibility.
| Material | Key Properties | Compatible Processes | Typical Applications |
| Photopolymer | Cure with UV light, fine detail, smooth finish, clear/opaque, flexible/rigid options, high detail resolution. Limited durability, not UV stable | SLA, DLP, PolyJet, Material Jetting 3D printing | Aesthetic/concept models, intricate designs, high-precision parts, master patterns, molds, jewelry, dental appliances, surgical guides, medical models, optical components, elastomeric surfaces |
| Epoxy | High strength (tensile, compressive, impact), excellent detail reproduction, chemical/heat resistant, electrical insulator, low shrinkage, durable | SLA 3D printing, casting, coating | Master patterns, molds, structural components, coatings, adhesives, aerospace/electronic applications, sealing tanks |
| Polyurethane | Wide hardness/flexibility range, durable, fast curing, good abrasion resistance, temperature/water resistant, minimal creep/shrinkage, user-friendly | Casting, molding, SLA 3D printing | Durable prototypes, casting/molding, jewelry, clear casts, prototypes integrating multiple materials (wood, metal, etc.) |
| Silicone | Highly flexible, captures intricate detail, variable hardness, temperature/water resistant, biocompatible, low toxicity, good adhesion, low creep/shrinkage | Casting, molding, SLA 3D printing | Molds, complex geometry prototypes, gaskets, seals, O-rings, medical devices/implants, microfluidic components, flexible prototypes |
Metals
Metals provide strength, durability, and resistance to high temperatures and corrosion, making them suitable for functional prototypes in demanding applications.
| Material | Key Properties | Compatible Processes | Typical Applications |
| Aluminum | Lightweight, high strength-to-weight ratio, corrosion resistant, thermally/electrically conductive, recyclable, machinable, ductile, affordable | CNC machining, DMLS/SLM 3D printing, die casting, extrusion | Functional prototypes (aerospace, automotive), lightweight structures, heat exchange components, rapid tooling, marine parts, architecture, pipes, furniture, tools, packaging, mechanical parts |
| Stainless Steel | Durable, corrosion resistant, high strength, high-temperature resistant, formable, weldable, relatively lightweight/inexpensive | DMLS/SLM 3D printing, CNC machining, sheet metal fabrication | High durability needs, chemical/acid exposure parts, cutlery, surgical tools, industrial components, heat exchangers, pharma/photo equipment, pumps, marine parts, aerospace, medical instruments, jewelry |
| Titanium | Very high strength-to-weight ratio, biocompatible, performs well at various temperatures, robust, lightweight, elastic, non-reactive, non-toxic, anti-rust/corrosion | DMLS/SLM/EBM 3D printing, CNC machining | Medical implants, high-performance components, aerospace/aeronautical (propellers, engines), laptops, art/architecture, armors, mining/power plant/petroleum parts, jewelry, prosthetics |
| Metal Powders | Essential for metal additive manufacturing, tailored properties, high purity, controlled particle size. Can be costly, oxidation risk | DMLS, SLM, EBM, Binder Jetting, LPBF, DED, MIM | Complex geometries, rapid prototyping, small-batch production, surface coating, powder metallurgy, aerospace/automotive parts, medical devices, electronics, tooling, dental implants |
| Maraging Steel | Ultra-high strength, tough yet malleable, easily heat treatable (high hardness), good machinability (initial state), high-temp resistant, good thermal conductivity | DMLS/SLM 3D printing | High wear components, dies, tooling (injection molding, die casting, punching, extrusion), high-performance industrial/engineering parts (aerospace, motor racing) |
| Tool Steel | High hardness, wear/abrasion resistant, high mechanical resilience, ductile, tensile, withstands elevated temps (up to 400°C). Generally not corrosion resistant | DMLS/SLM 3D printing, investment casting, CNC machining | Investment casting tools, pressure/injection molding tools, complex tools/components (high load), cutting tools, dies, aerospace/aviation components |
| Nickel Alloys | Excellent corrosion/oxidation resistance, high strength, high heat resistance (up to 980°C), ductile, often magnetic, weldable (with care), low thermal expansion (many) | DMLS/SLM/EBM 3D printing, powder metallurgy | Chemical/semiconductor industries, harsh environments (marine, chemical plants), high-temp structural (aircraft engines, gas turbines), medical devices, aerospace, automotive, energy, shielding |
| Cobalt Chrome | High strength-to-weight ratio, creep/corrosion resistant, very high strength/hardness, good thermal conductivity, biocompatible, machinable | DMLS/SLM/EBM 3D printing | Aerospace components (turbine engines, fuel nozzles), medical instrumentation/implants (orthopedic, dental), high-temp engineering, automotive, industrial equipment |
| Precious Metals | Gold: Unreactive, no tarnish, dense, malleable, ductile, alloys add strength/hardness. Silver: High electrical/thermal conductivity, soft, ductile, malleable | Gold: LBM, Binder Jetting, Wax Casting 3D printing. Silver: Wax Casting | Gold: Jewelry, watches, dental fillings/crowns, decorative items, electronic connectors. Silver: Jewelry, photography, dental alloys, electrical contacts, batteries, silverware |
Composites
Composites combine materials, like fibers within a polymer matrix, to achieve superior properties such as high strength-to-weight ratios, often exceeding those of individual constituent materials.
| Material | Key Properties | Compatible Processes | Typical Applications |
| Carbon Fiber | Exceptional strength-to-weight ratio, high tensile strength/stiffness, fatigue resistant, thermally stable, low thermal expansion. More expensive | CFF 3D printing, prepreg molding, machining | Weight-critical apps (aerospace, automotive), structural components, electronic enclosures |
| Glass Fiber (GFRP) | Good lightness/strength balance, design flexibility, good antishock/fatigue/corrosion resistance. Lower elastic modulus than steel, creep prone | 3D printing, pultrusion, molding | Structural components (marine, auto, construction, aerospace), civil engineering (bridges, roofs), electrical components, food packaging, piping |
Ceramics
Ceramics offer high hardness, temperature stability, electrical insulation, and chemical resistance, making them suitable for specialized prototyping needs.
| Material | Key Properties | Compatible Processes | Typical Applications |
| Porcelain | Excellent electrical insulation (even high temp), chemical resistant, high mechanical/dielectric strength, corrosion resistant, inert, low permeability | 3D printing (extrusion, binder jetting), slip casting, pressing, extrusion, injection molding | Electro-technical components, insulators, pottery (functional, decorative), construction items (bricks, tiles) |
| Silicon Carbide | High thermal stability, extremely hard, exceptional wear/mechanical strength, corrosion resistant, high thermal conductivity, zero shrinkage sintering | 3D printing (binder jetting, others), ceramic injection molding | High thermal/wear/hardness needs: cutting tools, seals, bearings, wear-resistant parts, auto brakes/engines, heavy load structures, aerospace, heat shields, furnace components |
| Silica Glass | High chemical purity/resistance, high softening/thermal resistance, low thermal expansion, thermal shock resistant, high transparency (UV-IR), radiation resistant | Advanced 3D printing (e.g., Two-Photon Polymerization) | High temp/mechanical/chemical stability or optical needs: microfluidics, microoptics, life sciences tools, high-temp imaging systems |
Specialty Materials
Specialty materials cater to unique prototyping requirements, such as creating casting patterns or achieving specific aesthetic finishes like wood.
| Material | Key Properties | Compatible Processes | Typical Applications |
| Prototyping Wax | Extremely hard, exceptional machining (high detail), self-lubricating, self-releasing, high melt temp, low ash (good for casting), eco-friendly | CNC machining, Lost Wax Casting | Master models/patterns for casting (automotive, jewelry, aerospace), verifying CNC programs, molds |
| Wood-filled Filaments | Wood-like finish/texture, biodegradable, good compressive strength. Low thermal resistance, fragile, sensitive to wall thickness | FDM 3D printing | Decorative items (sculptures, vases, frames), personalized accessories, home decor, architectural models, dioramas (where wood look desired) |
Key Considerations for Material Selection
Selecting the right material is crucial and involves balancing the prototype’s intended function and required properties against factors like process compatibility, budget, and timeline.
- Functional Requirements: What will the prototype do? (Structural testing vs. aesthetic evaluation)
- Material Properties: Match needs (strength, flexibility, temperature/chemical resistance, etc.) to material characteristics
- Process Compatibility: Ensure the material works with available prototyping methods (FDM, SLA, CNC, etc.)
- Budget: Material costs vary significantly (e.g., PLA vs. engineering resins/metals)
- Timeline: Consider production speed (e.g., FDM often faster than DMLS)
- Accuracy & Detail: Choose processes/materials suited for required precision (e.g., SLA/DLP for fine details)
- Post-Processing: Factor in time/cost for finishing (sanding, painting, curing, etc.)
HordRT: Your Partner in Rapid Prototyping
Choosing the right material and process is critical, and partnering with experienced professionals can streamline this complex task. For over a decade, the HordRT technical team has specialized in rapid prototype tooling, developing unique standards to balance quality, speed, and cost effectively. By focusing on research, design, and fabrication, HordRT helps both startups and established brands leverage rapid manufacturing processes to create competitive prototypes and products affordably, aiming for a win-win outcome by minimizing costs and maximizing customer benefits.
Conclusion
As technology progresses, we can anticipate even more exciting developments in rapid prototyping materials. The focus will likely continue to be on creating materials with enhanced performance characteristics, improved sustainability, and greater ease of processing. Innovations in multi-material printing and nanocomposites are already expanding the possibilities for creating complex prototypes with tailored properties.
Staying informed about these advancements, and leveraging the expertise of partners like HordRT who offer diverse manufacturing processes, will be crucial for product developers and engineers looking to leverage the full potential of rapid prototyping to accelerate innovation and bring better products to market faster.