3D Printing Filaments: Choose the Best Type for Your Project

In the dynamic world of 3D printing, the filament you choose can make or break your project, especially when it comes to the intricate realms of animatronics, props, or robotics that have both functional and aesthetic requirements. With an overwhelming number of 3D printing filament types on the market, each boasting unique properties and capabilities, selecting the right one becomes a crucial decision. Whether you’re crafting a lifelike animatronic creature, a cinematic prop, or a sophisticated robot, understanding the nuances of each filament type can be the difference between a successful creation and a failed experiment. Join me as we unravel the mysteries behind the different types of 3D printing filaments to help you make an informed choice, from printing mechanical components to decorative features, for your next masterpiece!

In This 3D Printing Filament Guide:

How to Choose the Best 3D Printing Filament

Choosing the right filament for animatronics, props, or robot projects requires an understanding of the unique demands these applications place on 3D printed parts. Unlike decorative items, models and static figures, when you 3D print parts that also need to function, there are additional filament characteristics like strength, flexibility, heat resistance and more to take into consideration. Here are a few of the most important factors to weigh when deciding on the best type of 3D printing filament for your project.

Mechanical Properties

• Strength: Can the filament withstand the mechanical stresses it will face?
• Flexibility: Does the 3D printed part need to bend without breaking?
• Durability: How long will the part last under regular use or stress?
• Impact Resistance: Can it absorb shocks without damage?

Thermal Properties

• Heat Resistance: If the 3D printed part will be near motors, electronics, or other heat sources, it needs to resist deformation at higher temperatures.
• Thermal Expansion: Some filaments may expand or contract significantly with temperature changes, affecting fit and function.

Electrical Properties

If you’re incorporating sensors, LEDs, or other electronics, consider:

• Conductivity: Some filaments are designed to be conductive.
• Insulation: Standard plastics like PLA, ABS, and PETG are insulators.

Chemical Resistance

Depending on the environment where your project will be used, the filament might need to resist oils, solvents, moisture, or other chemicals. Some 3D printing filaments are more chemical-resistant than others.

Ease of 3D Printing

• Bed Adhesion: Some filaments can be tricky to get to stick to the print bed.
• Warping: Filaments like ABS are more prone to warping if not printed in the right conditions.
• Print Temperature: Make sure your 3D printer can reach the required temperatures, especially for high-temperature materials like Polycarbonate.
• Support Removal: If your design has overhangs, consider how easy it will be to remove supports.

Aesthetic Properties

• Surface Finish: Some filaments have a glossy finish, while others are matte.
• Color & Transparency: Consider the range of available colors or if the filament can be transparent.
• Post-Processing: Will you need to paint, sand, or apply other finishes to your 3D printed part? Some filaments are easier and faster to post-process than others.

Cost

Specialty 3D printing filaments can be significantly more expensive than standard ones. Calculate whether or not the filament fits within your budget, especially for large prints.

Safety

• Fumes: Some filaments emit fumes that can be harmful if inhaled, needing better ventilation or filtration in your work environment.
• Flammability: Some plastics are more flammable than others.
• Biocompatibility: If the project is intended for prolonged skin contact, consider filaments designed for biocompatibility.

Environmental Considerations

• Biodegradability: Filaments like PLA are biodegradable, while others like ABS are not.
• Recyclability: Consider if the filament can be recycled after its lifespan.

Special Features

• UV Resistance: For projects exposed to sunlight, there are 3D printing filaments that have great UV resistance.
• Magnetic Properties: Some filaments are infused with iron, allowing them to be magnetized.
• Special Effects: There are exotic filaments that glow in the dark, change color with temperature, or have other unique features you can incorporate into your project.

Begin by thoroughly understanding the specific needs and challenges of your animatronic, prop, or robot project. Once you have a clear list of requirements, you can select the type of 3D printing filament that aligns best with those needs. If you’re unsure or having trouble picking between filaments, try test-printing small parts with different ones to evaluate their suitability before finalizing your choice. It’s far less expensive to pick the right type of 3D printing filament from the start rather than to get through a good deal of your project and then have to back track because the filament you chose doesn’t hold up to the job.

Types of 3D Printing Filaments

When it comes to animatronics, props, and robots, the choice of 3D printing filament can make a world of difference in terms of functionality, aesthetics, and durability. Each material has its unique strengths and challenges, so understanding the demands of your specific project is crucial in making an informed filament choice. Let’s look at each type of 3D printing filament more closely.

PLA

PLA (Polylactic Acid) is one of the most popular and widely used 3D printing filaments due to its ease of printing, decent strength for many applications, and biodegradability. It’s derived from renewable resources such as corn starch or sugarcane and comes in a variety of colors and finishes. It’s particularly suitable for decorative items, prototyping, and projects that don’t require significant durability or heat resistance.

Pros of using PLA for animatronics, props and robots:

• Ease of Printing: PLA prints well at lower temperatures and doesn’t require a heated print bed, making it user-friendly for beginners and compatible with most 3D printers.
• Dimensional Accuracy: PLA tends to warp less than materials like ABS, resulting in parts with good dimensional accuracy, which is crucial for fitting components together.
• Aesthetic Quality: It’s available in a wide variety of colors and finishes, including translucent, metallic, and glow-in-the-dark, making it versatile for decorative props.
• Cost: Generally, PLA is more affordable than many specialty types of 3d printing filaments.

Cons of using PLA for animatronics, props and robots:

• Lower Strength & Durability: While PLA is reasonably strong, it’s not as durable or impact-resistant as filaments like ABS, PETG, or Nylon. 3D printed parts under mechanical stress might wear out or break more easily.
• Low Heat Resistance: PLA begins to deform at relatively low temperatures (around 60°C or 140°F). For robots or animatronics with internal electronics or motors that generate heat, this can be problematic.
• Brittleness: Over time, especially when exposed to UV light or moisture, PLA can become brittle and more prone to breakage.
• Limited Flexibility: Unlike TPU or flexible nylons, PLA is rigid. This makes it unsuitable for parts that need to bend or flex.
• Post-Processing Limitations: PLA doesn’t respond well to certain solvents like acetone, which is often used to smooth or bond 3D printed parts. However, it can be sanded smooth and painted.

When Should You Use PLA 3D Printing Filament?

Versatile and eco-friendly, PLA is a popular choice among creators for its ease of use and broad color range. However, its big drawback lies in its lack of durability. Despite being prone to brittleness and warping under high temperatures, PLA excels in crafting decorative items, toys, and models.

Beginners benefit from its manageable printing process and affordability. By understanding PLA’s strengths and limitations, enthusiasts can harness its potential to create intricate designs while keeping in mind its susceptibility to wear and tear.

• Animatronics: PLA can be suitable for external, non-moving, or non-load-bearing parts. However, for internal mechanisms or parts that experience significant wear, you may prefer a more durable filament.
• Static Props: PLA is excellent for decorative props that don’t face rough handling or functional stress. It’s also good for props that are meant for short-term use or display.
• Robots: PLA is suitable for hobbyist robots or parts that aren’t exposed to high temperatures or significant mechanical stress. For industrial or heavy-duty robots, stronger filaments would be recommended.

ABS

ABS (Acrylonitrile Butadiene Styrene) is a type of 3D printing filament known for its strength, durability, and heat resistance. It’s fairly common in industrial applications because of its toughness and impact resistance. But unlike PLA and other 3D printing filaments, it’s made from petroleum-based materials and is definitely not biodegradable. ABS is often chosen for functional parts, prototypes, and any application that needs extra strength. Given its properties, it’s a popular material in industries like automotive for making car parts, toys (like LEGO bricks), and various consumer goods.

Pros of using ABS for animatronics, props, and robots:

• Strength & Durability: ABS is more robust and more durable than PLA, making it suitable for functional parts, especially those under mechanical stress.
• Heat Resistance: ABS has a higher glass transition temperature (around 105°C or 221°F) than PLA. This makes it more resistant to deformation under heat, useful for robots or animatronics with internal electronics or motors.
• Flexibility: While ABS is a rigid material, it has a degree of flexibility, making it less brittle than PLA. This can be beneficial for parts that require minor flexing.
• Post-Processing: ABS can be easily sanded and is soluble in acetone. This allows you to use an acetone vapor smoothing process, which can give parts a glossy finish and improve strength.
• Bonding: ABS parts can be glued together using acetone, making assembly of multi-part models easier.

Cons of using ABS for animatronics, props, and robots:

• Printing Difficulty: ABS can be more challenging to print with than PLA. It has a tendency to warp, so a heated bed is almost essential. Enclosed print chambers or heated chambers can further help reduce warping and layer separation.
• Fumes: When heated, ABS emits a strong odor and releases volatile organic compounds (VOCs). Ventilation is crucial, and some people may find the smell unpleasant.
• Environmental Impact: Unlike PLA, which is biodegradable, ABS is not. It’s derived from fossil fuels and is less environmentally friendly.
• Less UV Resistant: Prolonged exposure to UV rays can degrade ABS over time. If the parts are intended for prolonged outdoor use, this could be a factor.

When Should You Use ABS 3D Printing Filament?

Recognized for its robustness, ABS is probably the filament that brings the home 3D printer the closest to industrial results. Derived from petroleum-based materials, its durability is undeniable, though its non-biodegradable nature raises environmental concerns. Possessing impressive resistance to impacts and heat, ABS is available in a diverse spectrum of colors and finishes.

While it yields high-quality 3D prints notable for strength, its application comes with challenges. ABS warps, and the emission of fumes during printing is a drawback. But ABS is extremely valuable when printing functional components that demand endurance and resilience.

• Animatronics: ABS is an excellent choice for many animatronic parts due to its strength and durability. It can handle repeated movements and mechanical stresses better than PLA.
• Static Props: For props that might be handled frequently or could face some rough treatment, ABS is a suitable choice. Its ability to be smoothed and painted makes it versatile for creating realistic props.
• Robots: ABS is ideal for many robotic components, especially for hobbyist or semi-professional robots. Its balance of strength, heat resistance, and flexibility is beneficial for many robotic applications.

PETG

Combining the best properties of PLA and ABS, PETG (Polyethylene Terephthalate Glycol-modified) is a newer type of 3D printing filament gaining popularity in the 3D printing world due to its blend of user-friendly features and robust mechanical properties. It’s made from recycled materials and is also recyclable. PETG is suitable for a wide range of applications, including functional parts, mechanical components, protective components, containers that might hold liquids, and outdoor parts, given its UV resistance. Its balance of ease of printing, strength, and flexibility has made it increasingly popular among 3D printing enthusiasts and professionals alike.

Pros of using PETG for animatronics, props, and robots:

• Balanced Properties: PETG combines the ease of printing seen in PLA with strength and flexibility that approaches ABS. This blend of features makes it versatile for a range of applications.
• Durability: PETG has excellent layer adhesion, which results in prints that are less prone to splitting or delaminating under stress.
• Chemical Resistance: PETG is resistant to many chemicals, including some that can be a challenge for other common filaments.
• Moisture Resistance: Unlike some filaments that are hygroscopic (like Nylon), PETG is resistant to absorbing moisture, making it suitable for damp environments or outdoor applications.
• Low Warping: PETG has minimal shrinkage, which results in reduced warping during printing. This helps in achieving parts with better dimensional accuracy.
• Transparency: PETG can be semi-transparent, which might be an advantage for specific applications where visual monitoring or light diffusion is needed.
• Food Safe: While specific certification is needed for any direct food-related applications, PETG itself is generally considered food safe.

Cons of using PETG for animatronics, props, and robots:

• Stringing: PETG can be prone to stringing, which may require post-processing to clean up the 3D print. Fine-tuning retraction settings can help mitigate this issue.
• Surface Finish: While PETG offers a glossy finish, this might not always be desirable. Additionally, PETG prints may not be as smooth as those from other filaments.
• Heat Resistance: While PETG can handle higher temperatures than PLA without deforming, it doesn’t have as high a glass transition temperature as ABS.
• Abrasion: PETG is not as wear-resistant as some specialized materials like certain nylons, which might be more appropriate for high-wear components.

When Should You Use PETG 3D Printing Filament?

Incorporating the best parts of both PLA and ABS, PETG is a popular option. It’s made from recycled materials, which is a plus for many. It combines strength and durability with impact resistance and flexibility.

PETG’s intricacies during printing pose a challenge. You’ll have to heat treat it or hand-finish the piece, and you’ll pay a little extra for the pleasure. But that being said, PETG is still a great option for a range of applications.

• Animatronics: PETG’s strength and flexibility make it suitable for many animatronic parts, especially those that require some level of resilience without extreme flexibility.
• Static Props: PETG is an excellent choice for props that require a balance between appearance and durability. Its resistance to environmental factors is an added bonus.
• Robots: The strength and impact resistance of PETG can make it suitable for many robotic components, especially for those robots not exposed to high temperatures.

TPU

TPU, or Thermoplastic Polyurethane, is a type of flexible, elastic filament that’s widely used in 3D printing for applications requiring rubber-like flexibility and durability. Unlike most options on this list, these types of 3D printing filaments are stretchy, with excellent shock absorption and impact resistance.

Pros of using TPU for animatronics, props, and robots:

• Flexibility with Strength: TPU provides a balance between flexibility and strength. It can stretch and flex without easily breaking, making it ideal for parts that need to move or absorb impacts.
• Abrasion Resistance: TPU is resistant to wear and tear. In applications like robotics, where parts might undergo repeated movements or come in contact with various surfaces, this property is beneficial.
• Shock Absorption: Due to its elastic nature, TPU can absorb shocks and impacts, protecting other components in a system.
• Durability: TPU is resistant to oils, greases, and many chemicals, enhancing the longevity of printed parts, especially in environments where they might be exposed to such substances.
• Weather Resistance: TPU can withstand exposure to different weather conditions, making it suitable for outdoor robots or props.
• Smooth Movement: For animatronics, TPU’s flexibility can offer smoother, more lifelike movements compared to rigid materials.

Cons of using TPU for animatronics, props, and robots:

• Printing Challenges: TPU’s flexibility can make it a bit challenging to print, especially on 3D printers that don’t have a direct drive extruder. Retraction settings and printing speed might need fine-tuning to prevent stringing and blobbing.
• Structural Limitations: While TPU is strong for a flexible material, it’s not as stiff as materials like PLA, ABS, or PETG. For structural or load-bearing parts, TPU might not always be the best choice.
• Overstretching: If subjected to extreme stretching, TPU might not always return to its original form.

When Should You Use TPU 3D Printing Filament?

If you need a flexible 3D printing filament, TPE, TPU, and PTC are great options to deliver that coveted rubberiness. That’s why these materials have exceptional shock absorption and impact resistance.

Despite their ability to produce high-quality, flexible prints, working with them can be a pain. But those problems — like sagging and difficulty finishing — are precisely because of their rubber-like qualities. So you win some, you lose some.

• Animatronics: TPU is highly valuable, especially for components simulating organic, lifelike movement. Joints, tendons, or cushioning components in animatronics can benefit from TPU’s properties.
• Static Props: TPU is suitable for props that need some level of flexibility or soft touch. It’s great for costume components, flexible weaponry replicas, or any prop requiring a rubbery feel.
• Robots: TPU can be used for components that need shock absorption or flexibility, such as protective bumpers, grippers, wheels, or flexible connectors.

Nylon

Nylon (often referred to as Polyamide or PA) is an excellent type of filament for 3D printing parts, especially when strength, flexibility, and durability are required. Along with its toughness, Nylon is also available in a range of colors and finishes.

Pros of using Nylon for animatronics, props, and robots:

• High Strength and Durability: Nylon is known for its excellent strength-to-weight ratio, making it ideal for load-bearing components or parts that undergo significant stress like gears and moving parts.
• Flexibility: While not as flexible as TPU or TPE, Nylon offers a degree of flexibility, allowing it to resist breaking under pressure or impact.
• Wear Resistance: Nylon has excellent resistance to wear, abrasion, and fatigue, making it suitable for moving parts or components that experience frequent friction.
• Chemical Resistance: Nylon is resistant to many chemicals, including oils and greases, which can be beneficial in specific robotic applications.
• Low Friction Coefficient: Its natural slippery surface can be advantageous for gears, bearings, or any other part where reduced friction is desired.
• Temperature Resistance: Nylon can withstand higher temperatures than materials like PLA or even PETG, making it suitable for applications near heat sources.

Cons of using Nylon for animatronics, props, and robots:

• Moisture Absorption: Nylon is hygroscopic, meaning it absorbs moisture from the environment. This can affect its printing performance and mechanical properties. It often needs to be dried before printing and may require storage in a dry environment.
• Printing Difficulty: Nylon can be more challenging to 3D print with than PLA or PETG. It requires higher extrusion temperatures and may be prone to warping, requiring a heated print bed and possibly an enclosed print chamber.
• Cost: Nylon is generally more expensive than more common filaments like PLA or PETG.

When Should You Use Nylon 3D Printing Filament?

Nylon filament is renowned for its exceptional impact resistance and flexibility. Available in various colors and finishes, Nylon offers versatility in appearance, too — and that’s always a bonus in creative projects. But Nylon isn’t perfect. You need high temp printing, and you have to look out for warping and UV damage.

PA/Nylon is often employed in mechanical parts like gears, bearings, and mechanical components. That’s because it stands out as a choice material for those seeking structural integrity and reliability in their 3D prints.

• Animatronics: The strength and flexibility of Nylon make it suitable for internal mechanisms, joints, and other components that require resilience and a range of motion.
• Static Props: For durable props or those that mimic real-life functionality, Nylon is an excellent choice. Its wear resistance ensures the prop retains its appearance and functionality over time.
• Robots: Given its strength, flexibility, and wear resistance, Nylon is ideal for various robotic components, from gears to structural components. Its resistance to oils and greases can be an added advantage for certain robot applications.

PC

Polycarbonate (PC) is a high-performance type of 3D printing filament known for its exceptional strength, toughness, and heat resistance. When it comes to 3D printing functional parts, PC filament stands out due to its unique combination of mechanical and thermal properties, making it a great candidate for the most demanding applications.

Pros of using PC for animatronics, props, and robots:

• High Strength and Durability: PC is one of the strongest thermoplastics available. It can withstand significant force, making it suitable for load-bearing and high-stress components.
• Excellent Heat Resistance: Polycarbonate has a high glass transition temperature, typically around 147°C (297°F). This makes it great for applications close to heat sources or in high-temperature environments.
• Transparency: PC can be naturally transparent, which can be an advantage for specific applications where visual monitoring or light transmission is required.
• Flexibility: While not as flexible as materials like TPU, PC does have a degree of flexibility, which, combined with its strength, results in high impact resistance.
• Dimensional Stability: PC exhibits good dimensional stability, ensuring parts fit and function as designed.

Cons of using PC for animatronics, props, and robots:

• Printing Difficulty: Printing with PC can be challenging. It requires high extrusion temperatures (typically between 260°C and 310°C) and is prone to warping, so you’ll need a heated print bed and preferably an enclosed print chamber.
• Hygroscopic Nature: Like Nylon, PC is hygroscopic and absorbs moisture from the air. This can affect its print quality and mechanical properties. Proper drying before printing and dry storage is essential.
• UV Sensitivity: While PC is known for its clarity and is used in many optical applications, it is sensitive to UV light, which can lead to yellowing or degradation over time. If UV resistance is a factor for your project, you might need to look for specially formulated PC or apply protective coatings.
• Potential for Scratching: While PC is strong and impact-resistant, its surface can be prone to scratching. In applications where aesthetics are crucial, this might be a consideration.

When Should You Use PC 3D Printing Filament?

Polycarbonate (PC) filament, celebrated for its strength and enduring properties, excels in both impact and heat resistance. It also gives you plenty of variety in looks. While it is probably the strongest type of 3D printing filament you’ll be able to get your hands on and print with, working with the material isn’t easy. High heat is a must.

PC is the perfect filament for high performance elements, like automotive components and electronic enclosures. But because it has so many color and optical options, it’s able to serve in a variety of roles.

• Animatronics: Given its strength and heat resistance, PC is suitable for internal mechanisms and components of animatronics, especially if they’re exposed to stress or heat.
• Static Props: For props that require durability or might be subjected to rough handling, PC is an excellent choice. Its transparency can also be used for specific design elements.
• Robots: PC is ideal for structural components of robots, protective casings, or any part that needs to withstand wear and tear, impacts, or high temperatures.

Exotic 3D Printing Filaments

Delving beyond the realm of standard 3D printing filaments opens up a world of exotic materials, each offering unique properties tailored for specialized applications. Exotic 3D printing filaments refer to non-standard materials that often incorporate unique additives or are made from special formulations, differing from the common types of filaments like PLA, ABS, PETG, or TPU.

For animatronics, props, and robots, these types of 3D printing filaments can add not only functionality but also striking effects and realism that traditional filaments simply can’t match.

Know Your 3D Printing Filament Options

Choosing the right type of 3D printing filament is a critical first step for your project. And not all filaments are right for robots, animatronics, and motorized props. Remember, the 3D printing filament you opt for can influence your project’s aesthetics, functionality, and durability. By understanding the unique characteristics and applications of each filament type, you’re not just making a choice; you’re setting the foundation for your creation’s success. As the world of 3D printing continues to evolve, so too will the possibilities that new types of filaments will unlock. Here’s to pushing the boundaries of what’s possible, one 3D printed layer at a time!