by Melissa Donovan
There is major growth opportunity in the three-dimensional (3D) printing plastics market. Five main plastic categories—photopolymers, ABS/ASA, polyamide/nylon, polyactic acid (PLA), and other—are a focus for additive manufacturing (AM). The increasing supply of these plastics is part of the recent burst in interest.
Research firm Markets and Markets published its 3D Printing Plastics Market report in January 2024. The report states that the global 3D printing plastics market is expected to be worth USD 4.4 billion by 2028, growing at a compound annual growth rate of 22 percent during the forecast period of 2023 to 2028.
Growth is driven by demand for AM in industries such as automotive, healthcare, aerospace, and defense. Fueling demand is the development of innovative, stronger, lighter, and safer components and parts with reduced lead times and parts, according to the Markets and Markets’ report.
Major Growth
In general, the industrial 3D printing segment has experienced large amounts of growth over the past five to ten years.
“This is due to onshoring, current supply chain issues, cost of small batch production, and cost of labor,” says Matthew Stark, 3D segment manager, Mimaki USA, Inc. And this growth is set to continue, as Stark points out that “many companies/industries have not yet fully adopted 3D printing into their workflows.”
More specifically in regards to plastics, Nirup Nagabandi, Ph.D., VP of materials engineering, Nexa3D, believes 2024 is a pivotal year for 3D printing. “With a better understanding of the technology, more grades of new polymers come into the picture each quarter from various innovations, unlocking more applications. This enables the growth of polymer printing.”
The continuous introduction of new products is exactly why growth continues, agrees Michael Eggerdinger, business manager – 3D printing materials, BigRep GmbH. “There is a huge variety of printable materials that appear on the market almost every month. Parts can now be printed to fulfill a range of technical requirements, from strength and toughness to chemical resistance. There are plastics available that are flame retardant, others have specific ESD properties, or combine strength and elasticity. More industries see that there is a 3D printing material out there, tailored to their exact needs.”
While opportunity abounds, Francois Minec, global head of 3D polymers, HP Personalization and 3D Printing, believes it must be met cautiously. “The world has seen what can be achieved when we pursue innovation in design with powerful 3D printing technology. The demand is there, but it must be met in a way that is scalable and attainable for even more manufacturers across industries. Fortunately, 3D hardware, firmware, and software capabilities are enhancing thanks to increased integration of advanced data and KPI analytics, artificial intelligence, automation, and other emerging technologies.”
“Not only does this improve predictability, optimization, and consistency in application development all the way through to manufacturing for maximum yield rates, it achieves this all while keeping costs low. The benefit of reliability and repeatability across an entire fleet is a major industry improvement, making production scalable so that even more breakthrough polymer applications are brought to market easier and faster as business continues to grow into existing and new industry verticals,” continues Minec.
Realizing the full benefit of AM is a process in itself, according to Dr. Victor Roman, managing director, ARBURGadditive GmbH + Co KG. “The actual added value of AM only comes fully into its own when integrated functions, innovative applications, and completely new business models can be realized additively. It is always important to focus on the optimum materials and the ideal component design.”
Where the Opportunities Are
Automotive, healthcare, aerospace, and defense industries lead the charge when it comes to adopting 3D technologies, and plastic-based AM is no exception.
“There are growth opportunities in any company that manufactures, no matter the scale. 3D printing can be used to batch manufacture, assist in manufacturing—specialized jigs/tooling, or within the manufacturing workflow—prototyping, fit, and function. Industries that have adopted 3D printing—aerospace, automotive, heavy machinery—have extended their use of 3D printing dramatically over the last five to ten years and that momentum is not slowing,” shares Stark.
Minec believes industries offering mass-personalized goods receive the most value in regards to 3D printing plastics. Healthcare is one example, “where patient-specific parts such as prosthetics and orthotics can improve treatment and care.”
Agreeing with Minec, Nagabandi also sees substantial growth in healthcare. “We foresee growth in nanoscale 3D printing, particularly in microelectronics and biomedical applications like nanomedicine and drug delivery. Additionally, liquid metal printing, known for its speed and environmental friendliness, may gain prominence. These advancements open doors for personalized medicine and sustainable manufacturing.”
“One vision, for example, is to manufacture functional components on demand—decentrally and exactly where and when they are needed. I am thinking here, for example, of personalized implants that are 3D printed in the hospital at the same time as the operation. However, operating equipment and robotic grippers can also be additively manufactured very quickly, individually, and economically,” adds Roman.
Eggerdinger sees opportunity in “highly controlled” industries. “Industries that are highly controlled, and in which certifications are required for materials and production processes, like medical technology, transportation, food industry etc., are often reluctant to adopt new manufacturing technologies due to the high effort that this certification brings about. Aiding those industries to overcome these challenges, either by providing new and certified materials, or assisting in the relevant processes will help to address these markets.”
Minec also cites everyday consumer products that “can leverage highly personalized manufacturing methods to improve performance and experience for a range of customers. Companies like Brooks Running and Smith Optics deploy HP’s Multi Jet Fusion platform to ensure custom shoe fits while on running trails or mountain slopes.”
Plastic Categories
For the purposes of this article, we look at five main plastic categories—photopolymers, ABS/ASA, polyamide/nylon, PLA, and other. Each category is used by certain industries, for specific applications, and printed with various technologies.
Also, of note here is the form of the plastic. Markets and Markets classifies form by powder, filament, and liquid. The January 2024 report notes that the powder segment is expected to lead the market during the 2023 to 2028 forecast period in terms of value and volume.
Photopolymers
The 3D Printing Plastics Market report states that the photopolymer segment had the largest market share in 2022, in terms of value and volume. “Photopolymers are a type of 3D printing plastic that are transparent and used in liquid form in stereolithography (SLA). They are utilized for prototyping of static models in various end use industries,” notes the study.
“Photopolymers are mainly used when the surface finish plays a central role. Thanks to their low layer thicknesses, parts made from photopolymers generally require no post-processing. These materials have established themselves in the dental sector in particular and are also used to produce many design samples,” shares Roman.
SLA, as aforementioned, is a popular 3D printing process for photopolymers as it “can utilize a single photopolymer and produce low-cost, high-resolution parts with low material strength,” notes Stark.
Other 3D printing methods that use photopolymers include digital light processing (DLP) and continuous DLP, with each having its own benefits and disadvantages, adds Stark.
ABS/ASA
It is common to favor ABS/ASA for its ease of use and affordability.
“ABS is widely used due to its versatile properties, great aesthetics, ease of printing, and affordability at a business level,” shares Nagabandi. “Manufacturing aids such as jigs and fixtures; end use applications in consumer products, prosthetics, and housing/covers; prototyping; and low- and high-pressure tooling use a diverse range of plastics.”
A variety of manufacturers, colors, and variants are at a user’s disposal, notes Roman. “ABS/ASA is used in almost every industrial sector due to its range of materials and is probably the most frequently processed material group. Functional prototypes and end products are manufactured in the industrial environment. The material is also widely used in the maker scene.”
“ABS and ASA to a certain degree is a widely used material, particularly in the automotive industry. This popularity stems from its resilience against harsh environmental conditions, including extreme temperatures, and its ability to withstand impacts. These qualities make it a long-standing material choice for injection-molded parts across car interiors and exteriors,” notes Eggerdinger.
Roman thinks ABS’ popularity may change in the future, however. “The rapid industrialization of the 3D printing market will lead to increased processing of more technical and high-performance plastics. I would like to emphasize the group of biocompatible materials here, as 3D printing is perfectly suited to meeting individual requirements in the medical environment.”
Polyamide/Nylon
Polyamide/nylon is known for its strength.
Citing the mechanical properties of polyamides/nylon as superior to those of ABS/ASA, Roman says plastics are further improved with additives like glass or carbon fibers. As such, he finds that this group of materials is of particular interest to the automotive industry.
“We are experiencing high demand for additively manufactured components made from soft materials and short-fiber reinforced thermoplastics. Flexible connecting hoses and glass fiber-reinforced polyamides for the automotive industry are typical examples,” adds Roman.
Prototyping applications polyamides are used in include jigs, fixtures, and molds. “As a material that can withstand high levels of stress, engineers and designers can thoroughly test and refine designs with polyamides before moving to final production. For final part production, automotive, healthcare, consumer goods, and other industries leverage polyamides and 3D printing processes to manufacture precise and reliable end use parts, fulfilling the need for complex geometries to be brought to life,” says Minec.
A common printing method is powder bed fusion (PBF), this is due to the unique material properties. “Known for being an overall strong, tough, and durable material, polyamides are favored for a range of PBF applications, from automotive and medical to consumer goods, enabling enhanced productivity and reduced costs with advanced 3D printing technology,” shares Minec.
PLA
Due to PLA’s mechanical properties, Roman says it is used by makers and not so much in industrial environments.
“However, with evolving needs, we anticipate higher adoption of advanced materials like PEEK, carbon fiber reinforced materials, and PEKK, especially in end use applications, driven by their enhanced performance and suitability for various industries, such as aerospace and defense. High-performance materials like PEEK find applications in demanding environments due to their superior properties,” adds Nagabandi.
Other
Minec says thermoplastic elastomers and polypropylene are increasingly used. “They offer advantages for applications that require more flexibility, rebound resilience, or chemical resistance. With growing availability of material choices for plastic production, we can expect manufacturers and developers to more closely examine the material characteristics that specific applications require, tailoring selection to meet diverse manufacturing requirements effectively.”
“The processing of liquid silicone also warrants a mention. We see a high demand for the processing of Ultem, particularly in aircraft construction and medical technology,” adds Roman.
Bio-Based Plastic
Caster seeds, palm oil, and starches are natural sources from which 3D printing plastics—PA11, PA12, and PLA—are made. There is a rising demand for bio-based grades of materials due to awareness surrounding sustainability.
Minec says sustainability is shifting from consumers preferring eco-friendly products to demanding them. “This trend prompts more manufacturers to prioritize sustainability throughout their production processes, from research and development to final production, and especially regarding the materials they use.”
“Customized plastic parts made from innovative materials, including bio-based and recycled plastics, are an interesting development. In recent years, the demand for plastics made from renewable raw materials has risen noticeably. This trend is due to both increased environmental awareness and increased efforts and regulations to reduce the environmental impact of plastics,” explains Roman.
One of ARBURG’s customers uses a freeformer printer, for example, to process granules made from corn starch into customized forks that can be easily returned to the natural cycle after use.
“In addition to the already established renewable raw materials, there are also promising approaches for the production of new bio-based plastics. One example of this is research into the use of algae as a starting material. Developments in this area are increasingly important for 3D printing and we are keeping a close eye on them,” admits Roman.
To reduce the content of crude oil-based chemicals in their compounds, suppliers are creating some unusual materials, according to Eggerdinger. “This includes materials made from wood fibers, for example, while others are created using bacteria supported fermentation. These materials are not only fully bio-based but are also fully bio-degradable. Such considerations will surely play an increasing role in the future.”
Recycling and buyback programs are also being addressed. They allow customers to sell used PA11 and PA12 powders and printed parts, rather than dispose of them. “With these programs, these inherently eco-friendly materials contribute to a circular economy, enhancing their recyclability and availability while centralizing production. The synergy between 3D printing and bio-based materials fosters increased adoption and availability of both resources, highlighting each other’s capabilities and driving innovation in manufacturing,” shares Minec.
Continued Interest
As 3D printing technologies evolve, users of the technology are forced to adapt. This means branching out and attempting to try something new, like plastics. Or perhaps fulfill sustainable manufacturing goals and turn to natural resources from which plastics are made. In either case, 3D printing of plastics continues to grow. Users from automotive, healthcare, aerospace, and defense industries are prime candidates.
Apr2024, Industrial Print Magazine
