Not all Fused Deposition Modeling (FDM) 3D printers are the same. Some are based on a Cartesian system, others are based on the Delta model. Some have open print beds, while others have enclosed print chambers. And some utilize direct drive extrusion, while others use a bowden system. These different choices can initially seem overwhelming—after all, how should you know what’s the best option for your 3D printing needs if you’re new to the technology—so we want to help demystify them. Today, we’re looking specifically at direct drive vs bowden extrusion systems to understand how each works, how they differ, and what their respective benefits are.&nbsp;To start things off, it’s first important to understand how FDM 3D printers are set up. If we look at the basic components of a desktop 3D printer, you’ll find the build platform, the printhead (where the melted filament comes out of the nozzle), and the extruder (which is responsible for feeding filament into the printhead). Whether we’re talking about a direct drive or bowden system, the extruder always consists of at least a motor and drive gears, which control the filament’s movement through the printhead. The placement of the extruder and the feeding technique are what distinguish direct drive from bowden. Let’s dive in.<h2 dir="ltr">Direct Drive Extrusion&nbsp;</h2>In the case of direct drive extrusion, the extruder is mounted directly onto the printhead. This means that the filament is fed directly into the printhead, and the extruder moves with the printhead along the machine’s axes as it prints. The proximity of the extruder to the nozzle has the benefit of promoting consistent extrusion as well as retraction, which can lead to superior print outcomes in terms of filament precision. Another consequence of mounting the extruder directly onto the printhead is that the extruder does not require a particularly powerful stepper motor, since the filament is not traveling far from the gears to the nozzle.Direct drive extrusion is best suited for Cartesian and CoreXY 3D printer styles. These machines have the stability to support a heavier printhead. In some cases, the additional weight of the extruder on the printhead can inhibit print speeds and mobility due to increased vibrations.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjczNDE2NzM2NDQ3LTNkX3ByaW50aW5nLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" width="624" height="436" class="fr-fic fr-dii" alt="3D printer from above">Filament is fed directly into the direct drive extruder mounted to the printhead.<h3 dir="ltr">&nbsp; &nbsp; Advantages of Direct Drive Extruder</h3><ul><li dir="ltr">Delivers consistent extrusion thanks to the placement of the extruder on the printhead. Because the gears are positioned right above the nozzle, there is better control over extrusion and retraction.</li><li dir="ltr">The proximity of the extruder to the printhead also requires less motor power to feed the filament compared to the bowden extruder setup.</li><li dir="ltr">Direct drive extrusion works well with flexible materials as well as carbon fiber filament and other fiber-reinforced materials.</li></ul><h3 dir="ltr">&nbsp; &nbsp; Disadvantages of Direct Drive Extruder</h3><ul><li dir="ltr">One of the main cons of direct drive extrusion is that mounting the extruder onto the printhead adds substantial weight to the mobile printhead. This added weight can lead to greater vibrations, which can negatively impact the quality of your final print.</li><li dir="ltr">The weight of the direct drive extrusion systems can also impact print speeds.</li><li dir="ltr">Direct drive systems can make 3D printer maintenance more difficult, as it is harder to access parts within the printhead, such as the nozzle.&nbsp;</li></ul>Recommended reading: <a href="https://www.wevolver.com/article/tpu-print-settings" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">TPU print settings explained</a><h2 dir="ltr">Bowden Extruder</h2>A bowden extruder, or bowden tube extruder, is an extrusion mechanism that is mounted to the frame of an FDM 3D printer as opposed to the printhead. From its higher position, the bowden extruder feeds 3D printing filament from the spool through a PTFE tube (aka the bowden tube) into the printhead. The purpose of the tube is to keep the filament stable as it is fed into the printhead. Typically, the bowden tube diameter should not be much greater than the diameter of the filament. This ensures that the filament does not bend or flex as it is fed through. (Tubing for 1.75 mm filament is usually 2 mm in diameter, although it may be beneficial to use 1.9 mm or 1.85 mm tubing.)[1]&nbsp;The primary benefit of the bowden extruder is that it places the weight of the extruder onto the frame, resulting in a lightweight printhead, which can move along the printer’s axes with ease. It is also worth noting that using a bowden tube may require extra maintenance, such as cleaning.[2] If filament particles build up in the bowden tube, it can lead to problems like under extrusion.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjczNDE2ODQwMzY0LWJvd2Rlbl9leHRydWRlci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" width="624" height="459" class="fr-fic fr-dii" alt="closeup of 3D printer printhead">Bowden extruders place the weight of the extruder on the printer frame, enabling faster print speeds and smoother printhead movements.<h3 dir="ltr">&nbsp; &nbsp; Advantages of Bowden Extruder</h3><ul><li dir="ltr">Works well with PLA filament and can help minimize <a href="https://www.wevolver.com/article/3d-printer-stringing" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-redirect">stringing</a>.</li><li dir="ltr">As a lightweight extrusion system mounted on the printer’s frame, the bowden system promotes fast printing speeds, smooth printhead motions, and can result in higher quality prints.&nbsp;</li><li dir="ltr">The smooth movement of the printhead with a bowden extruder can minimize 3D printing problems such as ringing and ghosting.&nbsp;</li><li dir="ltr">A better option for Delta-style 3D printers, which are less stable than Cartesian 3D printers.</li><li dir="ltr">Allows for easier maintenance of printhead components, such as cleaning or replacing the hot end.</li></ul><h3 dir="ltr">&nbsp; &nbsp; Disadvantages of Bowden Extruder</h3><ul><li dir="ltr">Bowden extruders are not as suitable for flexible or fiber-filled abrasive filaments.</li><li dir="ltr">Because of the distance between the drive gears and the nozzle, the bowden extruder requires greater torque from the stepper motor to feed the filament. In other words: a more powerful motor is needed.</li><li dir="ltr">Bowden extruders are less responsive due to friction within the bowden tube. Retraction settings must account for this.</li><li dir="ltr">The bowden tube can wear down with repeated retraction in the 3D printing process, which can eventually lead to melted filament oozing out into the extrusion system. Using a heat break to create a buffer between the bowden tube and the hot nozzle can help mitigate this.[3]</li></ul>Recommended reading: <a href="https://www.wevolver.com/article/under-extrusion" target="_blank" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-redirect" rel="noopener noreferrer">How to fix under extrusion: Maintenance and print settings</a><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjczNDE2ODg4NDc1LWRlbHRhXzNkX3ByaW50ZXIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="624" height="459" class="fr-fic fr-dii" alt="delta 3D printer">Delta 3D printers typically use bowden tube extruders to enable greater mobility and minimize vibrations in the printing process.<h2 dir="ltr">Direct Drive System vs Bowden System - which one to use?</h2>When it comes down to it: there are pros and cons to both types of extrusion system. It really just depends on what your 3D printing priorities are. If you are interested in working with a range of filaments, such as flexible TPU and fiber-filled materials, then it’s safe to say a direct extruder is probably your best option. If you are primarily printing PLA, ABS, or another standard filament and print speed is a priority, then a bowden tube is likely the way to go.&nbsp;The type of 3D printer you are working with is also an important consideration. Cartesian printers as well as CoreXY machines tend to have more stable frames and motion control than Delta 3D printers. This means their printheads are better suited to handle the additional weight of the direct drive extrusion system. Delta printers benefit from less weight on the printhead and are thus a better match with bowden extruders. That being said, new direct drive extruder models are more lightweight and are thus more versatile.&nbsp;Recommended reading: <a href="https://www.wevolver.com/article/3d-print-ghosting" target="_blank" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-redirect" rel="noopener noreferrer">3D print ghosting causes and potential solutions</a><h2 dir="ltr">Key Takeaways</h2>When getting started with FDM 3D printing, it’s important to understand the different types of extruders that are out there. As we saw in this article, direct drive and bowden tube extruders are the two most common varieties. Here are the key takeaways from what we covered:<ul><li dir="ltr">Both direct drive and bowden extrusion systems use a stepper motor and drive gears to feed filament (push and retract) into the 3D printhead.&nbsp;</li><li dir="ltr">The key difference between the two extrusion systems is that direct drive extruders are mounted onto the printhead, while bowden systems are mounted onto the printer’s frame.&nbsp;</li><li dir="ltr">Direct drive extruders offer better extrusion and retraction control and the stepper motor requires less power to feed the filament into the printhead.</li><li dir="ltr">Direct extrusion works well with most filaments, including flexible filaments and fiber-filled materials.</li><li dir="ltr">Bowden extruders use a tube to feed the filament from the extruder to the printhead. They enable faster, smoother printing (less wobble) because there is no added weight on the printhead.&nbsp;</li><li dir="ltr">Bowden extruders are more suitable for Delta 3D printers, which have less stability than Cartesian machines.</li></ul><h2 dir="ltr">References</h2>[1] Hardy, Will. “Bowden vs Direct Drive Extruder”. E3D. November 2022. [Accessed January 2023]. <a href="https://e3d-online.com/blogs/news/bowden-vs-direct-drive" target="_blank" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">https://e3d-online.com/blogs/news/bowden-vs-direct-drive</a>&nbsp;[2] “How to clean the Bowden tube”. Ultimaker Support. November 2022. [Accessed January 2022]. <a href="https://support.makerbot.com/s/article/1667411551738" target="_blank" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">https://support.makerbot.com/s/article/1667411551738</a>&nbsp;[3] 3D Printing Canada. “DIRECT DRIVE VS BOWDEN TUBE”. Youtube. August 2022. [Accessed January 2023]. <a href="https://www.youtube.com/watch?v=QfENVzM7Krw" target="_blank" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">https://www.youtube.com/watch?v=QfENVzM7Krw</a>&nbsp;

Direct drive extruders feed the filament directly into the printhead using a stepper motor and drive gears.

Understanding the differences and benefits of direct drive and bowden extrusion systems.

Direct Drive vs Bowden Extruder for 3D Printing

Good bed adhesion is key to achieving defect-free prints. But how do you remove 3D prints that are stuck firmly to the build surface of the 3D printer? This guide reveals all.

How to Remove 3D Print from Bed: A Comprehensive Guide

Welding is as much an art as a science, but knowing where MIG and TIG processes perform best is key to success.

Metal inert gas (MIG) and tungsten inert gas (TIG) welding have their advantages and disadvantages, but how do you pick the process that's right for your next manufacturing or repair project?

MIG vs TIG welding: Picking the right process for joining metals

Strong materials are required for mechanical parts

When choosing between 3D printer filaments, strength is often a deciding factor. So what is the strongest 3D printer filament? And what does “strength” really mean here?

Strongest 3D Printer Filament: Choosing Between PC, Nylon, TPU, and Others

The difference between rigid and flexible parts is significant. Imagine if the caster wheels on your office chair were rigid and brittle, or if your wrench was made of rubber: you’d have scratched floors, and you’d never be able to loosen a nut from its bolt. The objects simply wouldn’t perform as they’re supposed to.Fortunately, FDM 3D printing accommodates the printing of both rigid and flexible parts. For rigid parts, the most common entry-level material is PLA, a low-cost and versatile thermoplastic with good strength. And there are plenty of other options too: POM and PVC are both great for rigid 3D printed parts, while ABS is solid but with a touch more flexibility than PLA.&nbsp;When printing flexible parts using an FDM 3D printer, the options are more limited, but you can still achieve excellent results. One of the best flexible filaments is TPU, a material from the TPE family with good durability, excellent abrasion resistance, and a high level of flexibility. TPU is harder to print than PLA but easier than other flexible materials.In some cases, the choice of TPU vs PLA is clear and obvious: if flexibility is what you need, TPU is the way to go. In other situations, however, it can be a more difficult decision. This article looks at TPU vs PLA in terms of the respective material characteristics of the 3D printer filaments, giving tips on which to choose in certain situations.<h2 dir="ltr" id="isPasted">What is PLA Filament?</h2>Polylactic acid, abbreviated as PLA, is the most widely used 3D printing filament for the fused deposition modeling (<a href="https://www.wevolver.com/article/fff-vs-fdm-is-there-any-difference" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">FDM/FFF</a>) printing process. Cheap, widespread, and biodegradable (it can be made from natural resources like corn starch or sugar cane), PLA nonetheless offers a good level of strength that is suitable for most prototyping projects.[1]PLA’s popularity in the world of extrusion 3D printing is also helped greatly by its low printing temperature, layer adhesion, and overall printability. Compatible with extruder temperatures as low as 180 °C and not requiring a heated bed, a spool of PLA is very easy to print, even at fast printing speeds. To improve <a href="https://www.wevolver.com/article/3d-print-not-sticking-to-print-bed-heres-the-solution" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">bed adhesion</a>, the print bed surface can be lined with painter’s tape, PEI, or glue stick.[2] In general, even beginner-level hardware can process PLA without issue — something that can’t be said of engineering materials, high-performance materials, or even other common 3D printing materials like TPU.The flip side of PLA’s printability is its low level of temperature resistance. A low melting point makes for easy printing, but it means that printed parts are <a href="https://www.wevolver.com/article/3d-print-warping" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-redirect">prone to deformation and warping</a> when subjected to high temperatures. Because of this, PLA is useless for end-use parts that go near heat (parts located near automotive engines, for instance). The material has other limitations too: while its rigidity can be a benefit, its brittleness makes it unsuitable for load-bearing applications.PLA filament is widely used to make 3D printed prototypes, consumer products, biodegradable medical devices, electronics housings, and plant pots.Recommended reading: <a href="https://www.wevolver.com/article/pla-recycling" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-redirect">PLA Recycling: Can PLA 3D Printer Filament be Recycled?</a><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjQ1NjAzMTMyOTM2LTNkX3ByaW50ZWQtcG90cy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib" alt="Multi colored plant pots">3D printed PLA plant pots<h3 dir="ltr" id="isPasted">PLA Filament Properties</h3><ul><li dir="ltr">Printing temperature: 180–230 °C</li><li dir="ltr">Print bed temperature: Unheated or 60–80 °C</li><li dir="ltr">Tensile strength: 50 MPa</li><li dir="ltr">Low flexibility</li><li dir="ltr">Medium durability</li></ul><h2 dir="ltr">What is TPU Filament?</h2>Thermoplastic polyurethane, known as TPU, is a flexible material that is part of the thermoplastic elastomer (TPE) family. Less elastic than other TPEs, TPU is highly durable, strong, and easier to extrude than other flexible filaments.TPU behaves partly like plastic, partly like <a href="https://www.wevolver.com/article/3d-print-rubber" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-redirect">rubber</a>, and there’s a good reason for this: the material is a block copolymer with alternating sequences of isocyanates (hard) and reacted polyol (soft). The ratio between these hard and soft segments can be altered by the material manufacturer, and this ratio ultimately determines the Shore hardness of the TPU.[3] Some applications demand a softer TPU material (i.e. 60A), while others are better with a firmer one (i.e. 95A).Although TPU is not the only flexible filament for FDM 3D printing, it is part of a small group. It also has very good abrasion resistance, chemical resistance (oil and grease), and fairly high shear strength. It is quite difficult to print (<a href="https://www.wevolver.com/article/tpu-print-settings" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-redirect">low print speeds are required</a>) but still easier than other TPEs and exhibits a low level of shrinkage. It requires PEI or painter’s tape applied to the build surface.Note that in other manufacturing processes (injection molding and stereolithography, for example) flexible parts are often made using thermosets: polymers that are liquid at room temperature and cured to become solid, after which they cannot be returned to their liquid state. There are plenty of flexible thermosetting materials, but these are incompatible with extrusion 3D printers since they cannot be melted and reformed. TPU is special because, although it is a thermoplastic, it offers material properties comparable to elastic thermosets.TPU filament is often used to make parts like caster wheels, phone cases, vibration dampeners, wearables, gel shoe orthotics, and soft-grip handles. Highly elastic TPU formulations can be used for items like gaskets and tubing.[4]Recommended reading: <a href="https://www.wevolver.com/article/what-is-tpu-material-in-3d-printing-material-properties-applications-and-technologies" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">What is TPU Material in 3D printing: material properties, applications, and technologies</a><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjQ1NjAzMjA1MDczLTNkLXByaW50ZWQtc2hvZS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib" alt="Green shoe 3d printed">3D printed TPU shoe<h3 dir="ltr" id="isPasted">TPU Filament Properties</h3><ul><li dir="ltr">Printing temperature: 225–235 °C</li><li dir="ltr">Print bed temperature: Unheated</li><li dir="ltr">Tensile strength: 20–55 MPa</li><li dir="ltr">High flexibility</li><li dir="ltr">Medium durability</li><li dir="ltr">Shore hardness range: 60A–95A</li></ul><h2 dir="ltr">TPU vs PLA: Which One to Choose?</h2>When faced with the choice of TPU vs PLA, 3D printer users are confronted with one obvious fact: TPU is a flexible filament, while PLA is a very rigid one. But there are other factors to consider too.Flexibility and rigidity are the main differentiating factors between TPU and PLA, so we’ll start our comparison there. Having read the previous section, it should be evident that TPU is a great material for making flexible, bendy, elastic, rubbery, or squishy 3D printed parts, while PLA is not. So if you need a 3D printer filament for an item like a shock absorber, a gasket, or a protective phone case, TPU may be an excellent choice. Conversely, if you need a stiff plastic component, PLA is the better option.Of course, you might be making parts that do not require a particularly high level or flexibility or stiffness. In that case, you might consider other important factors such as heat resistance: TPU requires a higher extruder temperature, but TPU parts consequently maintain their shape and function even at high temperatures. PLA parts, meanwhile, will begin to soften at around 60 °C so are only useful at low or normal temperatures.Another difference between TPU and PLA is tensile strength, where PLA comes out on top. Although TPU offers better durability, polylactic acid is the stronger of the two 3D printing filaments. However, TPU prints have the upper hand when it comes to abrasion resistance.Finally, the choice of PLA vs TPU may ultimately come down to simple factors like cost and printability. PLA wins out in both cases: TPU can be around three times more expensive than PLA on platforms like Amazon and is also more difficult to print, especially for beginners.<h1 dir="ltr" id="isPasted">Combining TPU and PLA in Multi-Material Prints</h1>TPU vs PLA can be combined in multi-material prints. This approach takes advantage of the unique properties of each material to create objects with enhanced functionality and aesthetics.Combining the materials in this way is similar to the injection molding technique of overmolding, which typically involves making a rigid molded component, then molding a further layer of (flexible) material over the top to improve ergonomics, grip, or shock absorption.The simplest way to combine TPU and PLA is to print separate TPU and PLA components and assemble them afterwards using adhesives, fasteners, interlocking sections, or another method.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1MTMzMDE4MzA1LXRvb3RoYnJ1c2guanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib" alt="toothbrush">PLA and TPU can be combined as with the hard and soft segments of an overmolded toothbrush<h3 dir="ltr">Dual Extrusion Technology</h3>To successfully combine TPU and PLA in a single print without further assembly, dual extrusion technology is required. Dual extrusion 3D printers have two separate print heads, each loaded with a different material. This allows the printer to switch between materials during the printing process, enabling the creation of complex multi-material objects.When designing multi-material prints that combine TPU and PLA, you will generally need to design the part as an assembly — a set of connected components — in the CAD software, rather than a single object. Different materials can then be selected for the individual components at the slicing stage.In this way, TPU can be used to create flexible joints or hinges within a predominantly PLA structure, for example. This can result in objects with moving parts or adjustable features. Conversely, PLA can be used to provide structural support and rigidity to a primarily TPU object, enhancing its strength.However, a major challenge when combining TPU and PLA in a multi-material print is a lack of chemical bonding, which means the materials do not naturally stick together well. For this reason, creating a mechanically interlocking connection between the two materials can make the part more secure and useful. Researchers have also studied the best kind of surfaces for creating a bonded interface between the two materials.[5]Fortunately, combining the two materials with a mechanical connection is easier than ever. Cura version 5.3 and beyond comes with a <a href="https://ultimaker.com/learn/unlock-true-multi-material-printing-with-ultimaker-cura-5-3/" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">Generate Interlocking Structure</a> feature that automatically creates a secure interlocking area. At the moment, <a href="https://www.wevolver.com/article/printing-tpu" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">printing TPU</a> with PLA is described as "experimental."&nbsp;<h2 dir="ltr" id="isPasted">Conclusion</h2>PLA and TPU are two very different materials, so they are not usually considered direct alternatives to one another. However, many 3D printer users will keep a stock of rigid 3D printing filament like PLA and a stock of flexible filament like TPU, putting a range of material properties at their disposal. To conclude, here is a simple table showing when to choose PLA and when to choose TPU:<div align="left" dir="ltr"><table><tbody><tr><td>PLA is better for…</td><td>TPU is better for…</td></tr><tr><td>Rigid parts</td><td>Flexible parts</td></tr><tr><td>Strong parts</td><td>Durable parts</td></tr><tr><td>Affordable parts</td><td>Temperature-resistant parts</td></tr><tr><td>Easy-to-print parts</td><td>Abrasion-resistant parts</td></tr><tr><td>Food-safe parts</td><td>Oil-resistant parts</td></tr></tbody></table></div><h1 dir="ltr" id="isPasted">FAQs</h1>What is the main difference between TPU and PLA?TPU is a flexible, elastic, and durable material, while PLA is a rigid, biodegradable material that is easier to print with.Can I use both TPU and PLA in the same print?Yes, you can use both materials in the same print if your 3D printer supports multi-material printing. This allows you to take advantage of the properties of both materials in a single object.Which material is better for prototyping and functional parts?It depends on the requirements of the specific part. TPU is better for parts that require flexibility and durability, while PLA is more suitable for rigid parts with fine details.Is PLA or TPU more environmentally friendly?PLA is a biodegradable material made from renewable resources, making it more environmentally friendly than TPU. However, TPU can be more durable and long-lasting, potentially reducing waste in certain applications.What are some common applications for TPU and PLA?TPU is commonly used for wearable items, flexible parts, and objects that require impact resistance. PLA is often used for decorative prints, prototypes, and rigid parts with fine details.<h1 dir="ltr">References</h1>[1] Humphreys R. <a href="https://polymerinnovationblog.com/from-corn-to-poly-lactic-acid-pla-fermentation-in-action/" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">From Corn to Poly Lactic Acid (PLA): Fermentation in Action</a> [Internet]. Polymer Innovation Blog. Innocentrix, LLC; 2012 [cited 2022Jan3].[2] <a href="https://ninjatek.com/learn/3d-printing-materials/pla/" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">3D printing with PLA</a> [Internet]. NinjaTek. 2021 [cited 2022Jan4].[3] <a href="https://www.lubrizol.com/Engineered-Polymers/About/What-is-TPU" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">What is TPU?</a> [Internet]. Lubrizol. [cited 2022Jan3].[4] <a href="https://prod.americanchemistry.com/industry-groups/center-for-the-polyurethanes-industry-cpi/resources2/library/thermoplastic-polyurethanes-bridge-the-gap-between-rubber-and-plastics" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-redirect">Thermoplastic polyurethanes bridge the gap between rubber and plastics</a> [Internet]. American Chemistry Council. 2002 [cited 2022Jan4].[5] Brancewicz-Steinmetz E, Sawicki J, Byczkowska P. <a href="https://www.mdpi.com/1996-1944/14/21/6464" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">The influence of 3D printing parameters on adhesion between polylactic acid (PLA) and thermoplastic polyurethane (TPU)</a>. Materials. 2021 Oct 28;14(21):6464.

TPU vs PLA comes down to what kind of printed parts you need

FDM 3D printer users who want more elasticity from their prints often turn to TPU filament, a flexible alternative to PLA with numerous benefits. But what else should you consider when looking at TPU vs PLA?

TPU vs PLA: Choosing Between Flexible and Rigid Filament for 3D Printing

At the beginning of the 2010s, consumers and professionals looking for an affordable 3D printer had only one option: fused deposition modeling (FDM). Initially developed by additive manufacturing giant Stratasys, FDM technology involves heating up strands of thermoplastic and depositing the molten material in successive 2D layers.In 2009, however, the Stratasys patent for FDM technology expired, which enabled a number of smaller companies to begin developing their own extrusion-style 3D printers, many of which were targeted at first-time buyers.[1] And as more and more products emerged on the market — Makerbot, Ultimaker, and others — prices rapidly decreased.But it wasn’t long before buyers had a second option for low-cost plastic 3D printing. By around 2012, companies like B9Creations and Formlabs were developing and marketing affordable 3D printers that used a completely different technology: vat photopolymerization. Instead of melting and extruding plastic, these printers used bright light to selectively cure liquid resin, producing parts with fine details and an exceptionally smooth surface finish. As with FDM, the market for SLA and DLP printers grew rapidly, and this had the effect of driving down prices.Since that time, filament and resin printing technologies have remained the two main options for consumer- and professional-level 3D printing of plastic parts. And since many consumers and professionals end up choosing directly between FDM and stereolithography 3D printers, this article aims to compare the two technologies side by side, looking at their respective pros and cons, as well as suitable uses for each.<h1 dir="ltr">What is SLA/DLP printing?</h1>Stereolithography (SLA) and digital light processing (DLP) are two closely related 3D printing technologies that both use liquid resin as a printing material. They can both be classified as vat photopolymerization technologies: the printing process takes place within a&nbsp;vat&nbsp;filled with liquid resin, and that resin undergoes&nbsp;photopolymerization, a light-induced chemical reaction where it changes from liquid to solid.So how exactly does resin 3D printing work? First, we’ll look at how photopolymerization 3D printing works in general, then we’ll see how SLA printers differ from DLP printers.<h2 dir="ltr">The resin 3D printing process</h2>Resin 3D printing technology relies on the process of photopolymerization. It uses liquid resin as a printing material, and this liquid can be turned into a solid when exposed to light. However, that doesn’t really explain how resin 3D printers are capable of creating highly detailed 3D objects such as prototypes, models, dental aligners, and jewelry patterns.To make 3D shapes, resin 3D printers work in ways that are broadly similar to other 3D printers. That is, they form successive layers of 2D shapes, resulting in a final 3D shape consisting of all those layers joined together. But their method of creating each 2D layer is highly unique: stereolithography and DLP 3D printers use a precise UV light source to cure a 2D pattern into the liquid resin; only the pattern area of the resin hardens, while the rest remains liquid.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1642437062330-stereolithography_3d_printer.jpg" style="width: 300px;" class="fr-fic fr-dib" alt="SLA am printer">SLA 3D PrinterIn order to create the following layers (and build up a 3D shape), a resin printer must create movement along the Z-axis — upwards or downwards. To achieve this, the build platform is lowered (or raised) in tiny increments after a layer has been cured.Once each layer has been cured, the hardened resin part can be removed from the 3D printer, ready for support removal and other post-processing steps. Any remaining resin can be kept and reused.The resins used for DLP and SLA printing — technically thermoset polymers — can be rigid or flexible. Some are marketed as high-strength engineering resins, while others are sold as castable resins that can be burnt out when used as patterns during investment casting.[2]&nbsp;<h2 dir="ltr">SLA vs DLP</h2>Stereolithography and digital light processing 3D printers do not use the same type of light source. SLA printers, which tend to be more expensive than DLP printers, use an ultraviolet (UV) laser to selectively cure patterns into the liquid resin.[3] These lasers effectively “draw” the pattern into the resin.DLP printers work in a different way. Instead of using a focused laser beam to draw a pattern, they use a projector lens and a series of tiny mirrors. This means that the entire 2D layer can be cured at once by flashing a 2D image into the resin tank, making the process faster than SLA.[4]A related form of resin printing is LCD printing, which is closer in nature to DLP than SLA. LCD resin printers use an LCD panel as a mask that goes between the light source and the resin in order to create 2D patterns; they are typically cheaper than both SLA and DLP systems.<h1 dir="ltr">What is FDM printing?</h1>Fused deposition modeling (FDM) — sometimes known as fused filament fabrication (FFF) — is the dominant form of 3D printing today. This is partly due to its popularity with beginners and hobbyists, though there are plenty of professional and industrial users of FDM 3D printers too: high-end FDM printers and materials can be used to make industrial parts, aerospace components, and tooling.FDM is a plastic 3D printing technology that uses spools of thermoplastic filament as feedstock. During the printing process, the filament is gently unwound from the spool, heated up, then deposited in layers using an extruder. Once the molten plastic is deposited (first onto the build plate, then onto subsequent layers) it cools down and solidifies, creating a hard plastic part. In some cases, the print bed is heated to improve bed adhesion.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1642437222682-filament_3d_printer.jpg" style="width: 300px;" class="fr-fic fr-dib" alt="3d printer that prints a filament">Filament 3D Printer To make each layer into a precise 2D shape, the printhead moves on rails along the X and Y axes while it deposits material from a nozzle. This linear movement is achieved via motors controlled by computer instructions. When a layer is complete, the printhead moves incrementally along the Z-axis (upwards) on another rail, then begins the next layer.Although it has its limitations, FDM is a versatile and reliable 3D printing process compatible with a huge range of plastic filaments; materials include affordable thermoplastics like PLA, engineering materials like polycarbonate, and high-performance materials like PEEK, as well as various blends and composites. Filament printing processes are most frequently used for prototyping, though they can also produce end-use parts.<h1 dir="ltr">Resin vs filament 3D printing</h1>Resin and filament 3D printing are two distinct processes that use different materials and technologies. As such, resin printed parts and filament printed parts can be very different.<h2 dir="ltr">Print quality</h2>On the whole, resin 3D printing processes can achieve better resolution, better surface finish, and can generally produce more high-quality parts than extrusion processes.When it comes to very fine features, a process like SLA can produce a high level of dimensional accuracy. Many SLA 3D printers are capable of printing layer heights as low as 25 microns, while most FDM 3D printers can only achieve around 100 microns.[5] Resin printers can also meet very tight tolerances.Resin printers also have the edge when it comes to surface finish. FDM 3D printing often produces layer lines (visible ridges between layers along the Z-axis) that need to be removed through sanding or other post-processing steps (which alter the final dimensions of the printed part). But SLA and DLP processes produce exceptionally smooth parts that require minimal post-processing besides support removal.Finally, parts printed with filament may be more susceptible to warping and deformation than those made from resin. This is due to the inevitable temperature fluctuations that occur during FDM printing.<h2 dir="ltr">Printed part durability</h2>While resin 3D printers can produce better quality parts than filament printers, they fall short when it comes to part strength and durability. Resin parts are often weak and brittle, so they have relatively few end-use applications.Not all filament is equally durable — PLA filament, for example, produces fairly brittle parts — but the huge range of material possibilities for FDM 3D printing means that very strong parts can be made. Affordable ABS filament can lead to durable parts that are tough and resistant to high temperatures, while more expensive plastics like polycarbonate and nylon produce even better results.Another advantage of filament 3D printing over resin 3D printing is its compatibility with composite materials. Thermoplastics like PLA and ABS can be reinforced with, for example, fiberglass or carbon fiber, making the printed parts far stronger.[6] This kind of reinforcement is not possible with liquid resins.<h2 dir="ltr">Build volume</h2>As a general rule, filament 3D printers have larger build areas than resin 3D printers. So while resin printers are great for highly detailed miniature parts, FDM is better for large prints.We can look at the build volumes of some market-leading products to see the difference. The incredibly popular Formlabs Form 2 SLA printer has a volume of 145 × 145 × 175 mm, which is smaller than popular FDM printers like the Ultimaker 3 (215 × 215 × 200 mm), Makerbot Replicator 2 (285 x 153 x 155 mm), and Prusa i3 MK3S (250 x 210 x 210 mm).Industrial large-format FDM 3D printers such as the BigRep Pro (1020 × 970 × 985 mm) and Stratasys F770 (1000 × 610 × 610 mm) offer huge build volumes but at a much higher price point than consumer FDM 3D printers.But while filament printing is generally better for large prints, it is possible to achieve large-format resin 3D printing if the stereolithography apparatus uses a top-down configuration rather than a bottom-up one. Bottom-up printers (i.e. most desktop resin printers) have a light source underneath the resin tank and build the part upside down. Top-down printers, however, have a light source above the resin tank and move the build platform downwards. More often used in industrial settings, these printers require a full tank of liquid resin but can print much larger parts.Within resin printing, SLA is better for large-format printing than DLP. DLP printers use projectors with a finite resolution (measured in pixels), so while it is technically possible to print large parts, resolution must be sacrificed to achieve the larger size. The principle is similar to using a video projector at home: if you place the projector close to the wall, the image will be small but sharp; if you move it further away, the image becomes larger but you can see the individual pixels.<h2 dir="ltr">Printing speed</h2>Comparing the printing speed of filament and resin 3D printers is difficult because there are many factors to consider.Firstly, not all resin printing technologies are the same: DLP is typically much faster than SLA, since it can cure a whole layer at once. However, since build volumes tend to be very small with DLP, it is usually not possible to print batches of objects during a single print job. So while the actual printing may be slower on SLA, it can achieve faster throughput if multiple units are required.FDM 3D printing sits somewhere between DLP and SLA when it comes to pure print speed, but some filaments must be printed very slowly to avoid warping and deformation. And again, filament 3D printers can have much larger build volumes than resin printers, which enables batch printing and faster throughput of duplicate parts.Finally, 3D printers (of all technologies) tend to have adjustable speeds, allowing the users to balance print times with print quality.<h1 dir="ltr">Conclusion</h1>Resin and filament 3D printers have their own unique characteristics and advantages, so when choosing between them, it is better to ask “what will the 3D printer be used for?” rather than “which 3D printing technology is better?”On the whole, resin 3D printers are best for producing small, detailed parts with an excellent surface finish. But filament printers come out on top when it comes to large or durable parts — especially those with demanding end-use applications. Resin printers are suitable for parts like castable patterns, visual prototypes, and dental devices, while filament printers offer a broader range of applications, including functional prototypes, industrial parts, and large-scale models.<h1 dir="ltr">References</h1>[1] Schoffer F. How expiring patents are ushering in the next generation of 3D printing [Internet]. TechCrunch. TechCrunch; 2016 [cited 2022Jan14]. Available from: <a href="https://techcrunch.com/2016/05/15/how-expiring-patents-are-ushering-in-the-next-generation-of-3d-printing" target="_blank">https://techcrunch.com/2016/05/15/how-expiring-patents-are-ushering-in-the-next-generation-of-3d-printing</a>[2] Formlabs 3D Printing Materials Library [Internet]. Formlabs. [cited 2022Jan14]. Available from: <a href="https://formlabs.com/uk/materials" target="_blank">https://formlabs.com/uk/materials</a>[3] Stereolithography [SLA] parts on demand: Stratasys Direct [Internet]. Stratasys. [cited 2022Jan14]. Available from: <a href="https://www.stratasysdirect.com/technologies/stereolithography" target="_blank">https://www.stratasysdirect.com/technologies/stereolithography</a>[4] SLA, DLP, and LCD resin 3D printer-what are the main difference? [Internet]. Creality. [cited 2022Jan14]. Available from: <a href="https://www.creality.com/blog-detail/sla-dlp-and-lcd-resin-3d-printer-difference" target="_blank">https://www.creality.com/blog-detail/sla-dlp-and-lcd-resin-3d-printer-difference</a>[5] Compare formlabs SLA 3D printers tech specs [Internet]. Formlabs. [cited 2022Jan14]. Available from: <a href="https://formlabs.com/uk/3d-printers/form-3/tech-specs/" target="_blank">https://formlabs.com/uk/3d-printers/form-3/tech-specs/</a>[6] Heidari-Rarani M, Rafiee-Afarani M, Zahedi AM. Mechanical characterization of FDM 3D printing of continuous carbon fiber reinforced PLA composites. Composites Part B: Engineering. 2019;175:107147.

When it comes to desktop 3D printing, buyers have two main options: resin printers that use photopolymerization technology, or filament printers that extrude molten thermoplastic. Both have their strengths and weaknesses.

Resin vs Filament 3D  Printers: Pros and Cons of Curing and Extrusion

One of the most common metallic elements on earth, aluminum has been processed as a pure metal in manufacturing since the early 19th century.[1] Today, metal is amongst the most popular in industrial manufacturing, used for objects as common as cans and kitchen utensils, to high-performance components in airplanes and rockets. It is, therefore, no wonder that from its beginnings, the metal additive manufacturing industry was interested in 3D printing aluminum and aluminum alloys.As we’ll see in more detail, the story of aluminum 3D printing has not been without its challenges, but thanks to innovations on the part of metal materials and hardware developers, aluminum alloys can now be 3D printed using various additive manufacturing processes to create high-quality, lightweight parts for numerous industries.<h2 dir="ltr">Applications of 3D Printed Aluminum</h2>There are countless applications for aluminum alloys using 3D printing technologies, but many of the most high-value end-use cases are found in the automotive and aerospace industries. For decades, traditionally manufactured aluminum and aluminum alloys have been used in these industries. In aerospace, for instance, aluminum alloys are used for aircraft wings and fuselage, as well as engine components. In the automotive industry, traditionally manufactured aluminum alloys are used for vehicle bodies, transmission, engine parts, and more. Aluminum has become such a widespread material in these industries—and others—due to its excellent strength-to-weight ratio. It goes without saying that the aerospace and automotive industries are constantly striving to reduce the weight of aircraft and vehicles to improve fuel efficiency—aluminum alloys have enabled them to achieve this while still meeting strength and durability standards.3D printing has opened up even more opportunities in aerospace and automotive for creating efficient parts with low weight. By leveraging intelligent, generative design, engineers can produce optimized components that cut back on weight while maintaining strength. Divergent Technologies, a company that developed a 3D printed supercar, created its own aluminum alloys for 3D printing and has used them to produce safety and suspension components.[2] American automotive giant Ford is working with aluminum AM on an even greater scale: in collaboration with ExOne, Ford is rolling out aluminum binder jetting with the aim of producing high-volume metal parts.[3]<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1645510208791-3d_printed_aluminium.jpg" style="width: 300px;" class="fr-fic fr-dib">Image:&nbsp;<a href="https://www.flickr.com/photos/theexonecompany/51026559252/in/album-72157718608148713/" rel="noopener noreferrer" target="_blank">ExOne</a>Some of the stronger aluminum alloys with excellent corrosion resistance are finding 3D printing applications in the aerospace industry. Though the material has a lower strength-to-weight ratio than titanium, aluminum is substantially cheaper as a raw material. Used in combination with metal 3D printing technologies, aluminum alloys are used for parts like heat exchangers that benefit from complex geometries and thin, strong walls. In 2021, Boeing demonstrated the successful use of a 3D printed flight critical component made from aluminum—a transmission housing—on a Chinook rotorcraft.[4] Aluminum AM is also being explored and implemented for the production of replacement parts for legacy aircraft.Of course, aluminum 3D printing is not only being used and explored in the automotive and aerospace industries: it also has applications in the spheres of industrial manufacturing, motorsport, cycling, energy, robotics, jewelry, and beyond. It is also suitable for prototyping and tooling.<h2 dir="ltr">Advantages and Disadvantages of 3D Printed Aluminum</h2><h3 dir="ltr">Advantages</h3>There are many reasons why demand and interest for aluminum 3D printing have grown in recent years. First, aluminum alloys offer beneficial material properties that meet the needs of many applications. For example, aluminum is lightweight compared to steel and nickel-based alloys, while still providing sufficient strength and hardness. Aluminum alloys also offer good thermal properties as well as corrosion resistance.3D printing, for its part, brings many advantages to the table compared to traditional manufacturing processes like CNC machining and sheet metal forming. Chief among these advantages is greater design freedom. Engineers and product designers can design aluminum parts with complex geometries, including lattices and internal channels, to optimize the performance and weight of production parts.&nbsp;Metal 3D printing technologies such as laser powder bed fusion, directed energy deposition, and binder jetting also allow for greater production agility. Specifically, users can speed up turnaround times for part development (by iterating, testing, and tweaking designs), can produce small or one-off production runs, as well as achieve mass customization. Depending on the technology, aluminum 3D printing also allows for high-precision and tight tolerances without extensive post-processing. Another important benefit offered by metal 3D printing is part consolidation. Complex assemblies, like heat exchangers, that would typically be made of several different components can be redesigned into a single, more efficient part, cutting down on production and assembly times.<h3 dir="ltr">Disadvantages</h3>Naturally, there are also disadvantages to 3D printing aluminum. Depending on the application at hand, there may be better metal alloys than aluminum-based alloys. For instance, titanium alloys offer a better strength-to-weight ratio than aluminum alloys, making them more common in aviation. Aluminum alloys for 3D printing are also not as strong as nickel-based alloys or steel. That being said, aluminum alloys are less expensive than titanium and are more lightweight than steel and nickel-based materials.Perhaps the biggest disadvantage of 3D printing aluminum is related to its printability. Fortunately, massive strides have been made in recent years: today, there are a variety of high-quality aluminum alloys specifically developed for additive manufacturing. In the earlier days of metal 3D printing, aluminum presented several challenges. Conventional aluminum alloys, such as 6061, 7075, and 2024, did not undergo powder bed fusion processes well due to their reactivity and were prone to cracking. Casting aluminum alloys, such as A357, while easier to print, were slow to process and had inconsistent mechanical properties due to poor melt pool stability and energy absorption.[5] Thankfully, these issues have been overcome or at least mitigated with the creation of specially tailored aluminum alloys as well as better powder quality.&nbsp;<h2 dir="ltr">How to 3D Print Aluminum</h2>The first step in 3D printing aluminum is metal powder production. Most aluminum alloy powders on the market today are made using gas atomization. This process is capable of producing powder particles with good sphericity, which is ideal for AM. It should be noted that the characteristics and quality of powder play a big role in how the final 3D printed component turns out. For instance, in laser powder bed fusion processes, sphericity and uniformity lead to better flow and packing, resulting in more reliable prints. Powder particle sizes also range on the micron scale.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1645510374536-laser_sintering.jpg" style="width: 300px;" class="fr-fic fr-dib" alt="DMLS-machine">Laser Sintering Machine for MetalIn terms of metal 3D printing technologies available for aluminum prints, there are a few options. The most common 3D printing processes for aluminum alloys are laser powder bed fusion-based including SLM (selective laser melting) and DMLS (direct metal laser sintering). These industrial technologies both rely on a laser energy source to either selectively melt or sinter thin layers of aluminum powder. The powder particles exposed to the laser fuse together and solidify. Once a layer is complete, another coating of aluminum powder is applied and the melting or sintering is repeated. This is continued until a three-dimensional object or series of objects are complete. From there, the parts must be removed from the loose powder and cleaned.&nbsp;Electron beam melting (EBM) is another PBF process that can print aluminum parts: it uses an electron beam in the 3D printer as an energy source instead of a laser. This process can actually have advantages compared to laser-based technologies, because the electron beam is less affected by the aluminum’s reflectivity, resulting in fewer thermal stresses and less risk of cracking.[6]Up until recently, binder jetting proved to be challenging for aluminum alloys. The binder jetting process is gaining prominence due to production speed compared to PBF and its capacity to use metal injection molding (MIM) metal powders, which are usually cheaper than AM powders. The problem has been that aluminum alloys have not been widely adapted for MIM in part due to their highly reactive nature. In binder jetting, a binding agent is selectively deposited onto thin layers of a dense metal powder, a process that is repeated layer by layer. The print results in a green part, which must then undergo debinding and sintering. These processes remove the binder and fuse the metal particles together to create a dense final component.Just in the past year, there have been significant advancements for aluminum binder jetting. ExOne and Ford developed a patent-pending process for binder jetting and sintering aluminum 6061—one of the most commonly used alloys.[3] Ricoh is also developing a binder jetting technology capable of processing aluminum alloys.[7] On the material side, Equispheres is pursuing the development of AlSi10Mg powders specifically tailored to binder jetting.[9]In addition to powder bed fusion and binder jetting processes, aluminum 3D printing can also be achieved using filament extrusion technologies. Aluminum filaments are made from a combination of metal powders and a polymer matrix. Wire Arc Additive Manufacturing (WAAM) has also been used to produce large-scale structures from aluminum alloys.<h2 dir="ltr" id="isPasted">Which Aluminum Alloys can be 3D Printed?</h2>Metal powder manufacturers as well as specialized AM powder producers offer a broad range of aluminum alloys for metal 3D printing. These materials are tailored for a range of different uses and applications, offering different properties and profiles. Many of the available aluminum alloys consist of a combination of metallic and metalloid elements, including aluminum, silicon, magnesium, and even copper.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1645510511598-Equispheres-Aluminum-alloy-powder-1024x747-2.jpg" style="width: 300px;" class="fr-fic fr-dib">Image: <a href="https://equispheres.com/wp-content/uploads/Equispheres-Aluminum-alloy-powder-1024x747.jpg" rel="noopener noreferrer" target="_blank">Equispheres</a>AlSi10Mg is among the most common additive manufacturing aluminum alloys. It is a casting aluminum alloy characterized by good strength, toughness, and corrosion resistance. Many metal AM material providers offer AlSi10Mg. Many other common aluminum alloys for AM, such as F357 (ALSi7Mg) and AlSi12, are casting alloys. These are easier to process than other types of the aluminum alloy due to their relatively low melting point. This class of 3D printing alloy typically contains silicon, which improves the metal’s weldability.There are also other aluminum alloys for additive manufacturing, which can offer superior properties to casting alloys. For instance, advances are being made to 3D print Al6061, a high-performance hardened aluminum alloy with excellent ductility, thermal conductivity, electrical conductivity, and corrosion resistance. Al7075 is another aluminum alloy that can be 3D printed. The alloy is characterized by its high zinc content and can be heat treated to achieve exceptionally high degrees of strength. Al6061 and Al7075 have traditionally been challenging to 3D print, but thanks to advances in powder quality and the right printing parameters, it is now a possibility.It is also worth quickly mentioning Scalmalloy, a high-strength metal 3D printing material made from a combination of scandium, aluminum, and magnesium.[8] This material is stronger than traditional aluminum alloys (thanks to the addition of scandium) and offers an excellent strength-to-weight ratio and good ductility. The material is particularly interesting to the aerospace industry.<h2 dir="ltr">Conclusion</h2>Aluminum has presented challenges and incredible opportunities for the additive manufacturing industry. Today, we are seeing in real-time how aluminum 3D printing is advancing, with previously “impossible” alloys like 6061 being printed and binder jetting for aluminum alloys finally being realized. All that to say, we are only at the beginning of aluminum AM and are bound to see more amazing applications for the material being developed, from automotive to aerospace and beyond.<h2 dir="ltr">References</h2>[1] How Products Are Made, 2022. “Aluminum”. [online] <a href="http://www.madehow.com/Volume-5/Aluminum.html" target="_blank">http://www.madehow.com/Volume-5/Aluminum.html</a> [Accessed January 12, 2022][2] RDN, 2019. “Divergent, SLM near series production of 3D-printed auto safety, suspension parts”. [online] <a href="https://www.repairerdrivennews.com/2019/11/20/divergent-slm-near-series-production-of-3d-printed-auto-safety-suspension-parts/" target="_blank">https://www.repairerdrivennews.com/2019/11/20/divergent-slm-near-series-production-of-3d-printed-auto-safety-suspension-parts/</a> [Accessed January 12, 2022][3] ExOne, 2021. “ExOne and Ford have announced the automotive industry's first binder jet 3D printing and high-density sintering of aluminum”. [online] <a href="https://www.exone.com/en-US/Ford-and-ExOne-Achieve-Scientific-Breakthrough" target="_blank">https://www.exone.com/en-US/Ford-and-ExOne-Achieve-Scientific-Breakthrough</a> [Accessed January 12, 2022]&nbsp;[4] Boeing, 2021. “Chinook Flies First Flight Critical, 3D-Printed Part on Rotorcraft”. [online] <a href="https://www.boeing.com/defense/ch-47-chinook/chinook-flies-first-flight-critical-3d-printed-part-on-rotorcraft.page" target="_blank">https://www.boeing.com/defense/ch-47-chinook/chinook-flies-first-flight-critical-3d-printed-part-on-rotorcraft.page</a> [Accessed January 12, 2022][5] Equispheres, 2021. “Aluminum can be as easy as titanium”. [online] <a href="https://equispheres.com/aluminum-can-be-as-easy-as-titanium/" target="_blank">https://equispheres.com/aluminum-can-be-as-easy-as-titanium/</a> [Accessed January 12, 2022][6] Mohammad Saleh Kenevisi, Feng Lin. “Selective electron beam melting of high strength Al2024 alloy; microstructural characterization and mechanical properties”, Journal of Alloys and Compounds, Volume 843, 2020. [online] <a href="https://doi.org/10.1016/j.jallcom.2020.155866" target="_blank">https://doi.org/10.1016/j.jallcom.2020.155866</a> [Accessed January 13, 2022][7] Ricoh, 2021. “Ricoh introduces aluminium metal binder jetting technology”. [online] <a href="https://rapidfab.ricoh-europe.com/ricoh-introduces-aluminium-metal-binder-jetting-technology/" target="_blank">https://rapidfab.ricoh-europe.com/ricoh-introduces-aluminium-metal-binder-jetting-technology/</a> [Accessed January 13, 2022][8] Equispheres, 2019. “Sintering Aluminum Alloys With Binder Jet Printer Technology Unfeasible Until Now”. [online] <a href="https://equispheres.com/press-release-sintering-aluminum-alloys-with-binder-jet-printer-technology-unfeasible-until-now/" target="_blank">https://equispheres.com/press-release-sintering-aluminum-alloys-with-binder-jet-printer-technology-unfeasible-until-now/</a>&nbsp; [Accessed January 13, 2022][9] APWorks, 2021. “Scalmalloy”. [online] <a href="https://www.apworks.de/scalmalloy" target="_blank">https://www.apworks.de/scalmalloy</a> [Accessed January 13, 2022]

Though aluminum 3D printing has traditionally been a challenge, big advances have been made in recent years. Here's everything you need to know about aluminum additive manufacturing, from applications and technologies, to what alloys are available.

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MIG vs TIG welding: Picking the right process for joining metals

Strongest 3D Printer Filament: Choosing Between PC, Nylon, TPU, and Others

TPU vs PLA: Choosing Between Flexible and Rigid Filament for 3D Printing

Resin vs Filament 3D Printers: Pros and Cons of Curing and Extrusion

3D Printed Aluminum: Everything You Need to Know