Materials Selection Guide - Part 3
Selection Matrix, Decision Trees & Application Guide
Selection Matrix, Decision Trees & Application Guide
With 20+ engineering materials available, selecting the optimal polymer requires balancing thermal requirements, mechanical properties, chemical resistance, cost, and printability. This guide provides decision frameworks, comparison matrices, and application-specific recommendations based on 40+ years of engineering experience.
Start with your most critical requirement and follow the decision path.
Excellent: PA12, PA6, PPS, PEKK, PEEK
Good: PETG, ASA
Poor: PC (attacked by oils)
Excellent: PPS, PEKK, PEEK (broad spectrum)
Good: PETG, PA12 (mild acids)
Poor: PC (attacked by alkalis), PA6 (hydrolysis)
Excellent: PPS, PEKK, PEEK
Good: PA6, PA12, PETG (alcohols)
Poor: PC (dissolved by acetone), ABS (acetone smoothing)
All materials at a glance. Sort by priority property.
| Material | HDT @ 1.8MPa | Tensile Strength | Modulus | Impact (Izod) | Print Difficulty | Relative Cost |
|---|---|---|---|---|---|---|
| High-Performance Polymers | ||||||
| PEKK | 250°C | 90-100 MPa | 3.6 GPa | 7-9 kJ/m² | Very Hard | $$$$ |
| PEKK-CF | 280°C | 150-200 MPa | 11-13 GPa | 10-13 kJ/m² | Very Hard | $$$$$ |
| PPS | 240°C | 80-95 MPa | 3.3 GPa | 2-3 kJ/m² | Very Hard | $$$$ |
| PPS-GF | 260°C | 140-180 MPa | 10-14 GPa | 5-8 kJ/m² | Very Hard | $$$$$ |
| PPA | 180-200°C | 80-110 MPa | 2.5-3.5 GPa | 5-8 kJ/m² | Hard | $$$ |
| PPA-GF | 260-280°C | 140-180 MPa | 9-12 GPa | 8-12 kJ/m² | Very Hard | $$$$ |
| Nylon Family | ||||||
| PA6 | 45-55°C | 45-55 MPa | 1.8-2.5 GPa | 5-8 kJ/m² | Moderate | $ |
| PA12 | 40-50°C | 50-60 MPa | 1.5-1.8 GPa | 8-12 kJ/m² | Moderate | $$ |
| PA6-CF | 90-110°C | 60-90 MPa | 5-7 GPa | 7-10 kJ/m² | Moderate | $$ |
| PA6-GF | 140-160°C | 90-140 MPa | 6-10 GPa | 5-8 kJ/m² | Hard | $$$ |
| Engineering Thermoplastics | ||||||
| PC | 128-133°C | 60-70 MPa | 2.2-2.4 GPa | 60-80 kJ/m² | Hard | $$ |
| PC-FR | 125-135°C | 55-65 MPa | 2.1-2.3 GPa | 50-70 kJ/m² | Hard | $$$ |
| PETG & ABS Families | ||||||
| PETG | 70-75°C | 50-55 MPa | 2.0-2.2 GPa | 7-10 kJ/m² | Easy | $ |
| PETG-CF | 75-85°C | 45-55 MPa | 4-6 GPa | 5-7 kJ/m² | Easy | $$ |
| ABS | 95-105°C | 40-45 MPa | 2.0-2.5 GPa | 15-25 kJ/m² | Moderate | $ |
| ABS-CF | 100-115°C | 50-70 MPa | 4-6 GPa | 10-15 kJ/m² | Hard | $$ |
| ASA | 95-100°C | 40-50 MPa | 2.1-2.3 GPa | 20-30 kJ/m² | Moderate | $$ |
$ = $30-50/kg | $$ = $50-100/kg | $$$ = $100-200/kg | $$$$ = $200-400/kg | $$$$$ = $400+/kg
Easy: No chamber, low warping | Moderate: Chamber helpful, some warping | Hard: Chamber required, significant challenges | Very Hard: Specialized equipment, expert tuning
High temperature, vibration, chemical exposure
Critical: Resistance to oils, fuels, antifreeze. High vibration fatigue resistance.
Fire resistance, low smoke, weight
Critical: FAA flame/smoke requirements. Weight reduction. Traceability.
Biocompatibility, sterilization, chemical resistance
Critical: USP Class VI certification. Gamma/EtO/autoclave compatibility.
Aesthetics, impact resistance, cost
Critical: Surface finish, color consistency, drop-test performance.
UV resistance, weathering, temperature cycling
Critical: UV stability, moisture resistance, thermal cycling (-40°C to +60°C).
Dimensional stability, wear resistance, cost-effective
Critical: Dimensional stability over time, wear on contact surfaces.
Low friction, wear resistance, fatigue
Critical: Coefficient of friction, fatigue life, dimensional stability.
Fire resistance, electrical insulation, heat dissipation
Critical: UL94 rating, dielectric strength, thermal dissipation.
Fast iteration, ease of printing, low cost
Critical: Print success rate, minimal post-processing.
When your first choice isn't available or practical.
Why substitute: PEEK difficult/impossible to FDM print. PEKK nearly identical properties but printable.
Trade-offs: PEKK ~5-10% lower mechanical properties. Much lower cost. Actually printable on FDM.
When to use: Any application specifying PEEK that doesn't require injection molding.
Why substitute: PA6-GF more abrasive, harder to print, higher cost.
Trade-offs: PA6-CF lower HDT (110°C vs 160°C). Easier printing. Lower cost.
When to use: Temperature <100°C, stiffness matters more than heat resistance.
Why substitute: PC very difficult to print (warping, drying, high temps).
Trade-offs: PA12 lower HDT (50°C vs 135°C), lower impact strength.
When to use: Temperature <80°C, printability more important than impact resistance.
Why substitute: UV resistance for outdoor use.
Trade-offs: ASA 1.5-2x cost. Slightly easier to print (less warping).
When to use: Any outdoor application. UV exposure. Color retention critical.
Why substitute: Much easier printing (no chamber), lower cost.
Trade-offs: PETG-CF lower HDT (75°C vs 110°C). Similar stiffness.
When to use: Room temperature application, fast turnaround needed.
Why substitute: PPA-GF easier to print, lower cost, wider availability.
Trade-offs: PPA-GF slightly lower HDT (260°C vs 280°C), lower chemical resistance.
When to use: Temperature <240°C, moderate chemical exposure.
PA6: $30-50/kg - Excellent mechanical properties for the price. Best for jigs, fixtures, functional prototypes where temp <80°C.
PETG: $25-35/kg - Easiest to print. Good for rapid prototyping, consumer products, low-stress applications.
PA12: $60-100/kg - Premium over PA6 justified by dimensional stability and ease of printing. Production-grade parts.
PA6-CF: $80-120/kg - 3x stiffness of PA6, higher HDT. Worth it for structural applications <130°C.
PC: $70-100/kg - Impact resistance justifies difficulty. Use when drop-test or toughness is critical.
ASA: $50-80/kg - UV resistance premium over ABS. Must-have for outdoor applications.
PPA-GF: $150-250/kg - High-temp (260°C HDT) at lower cost than PEKK. Best value in high-temp category.
PA6-GF: $120-180/kg - Highest stiffness (10 GPa), high HDT (160°C). Aerospace/automotive justified.
PEKK: $300-500/kg - Ultimate performance. Only use when PPA-GF insufficient (>250°C, extreme chemical).
PEKK-CF: $500-800/kg - Maximum stiffness + high temp. Aerospace only - cost rarely justified elsewhere.
| Temperature resistance | PEKK-CF (280°C HDT) |
| Stiffness | PEKK-CF (11-13 GPa) |
| Impact resistance | PC (60-80 kJ/m²) |
| Chemical resistance | PPS, PEKK |
| UV/outdoor durability | ASA |
| Dimensional stability | PA12, PPS |
| Fatigue resistance | PA12 |
| Overall printing | PETG |
| No chamber required | PETG, PETG-CF |
| No drying required | ABS, ASA |
| Best layer adhesion | PETG |
| Least warping | PETG |
| Support removal | PA6, PA12 |
| General purpose | PA6 ($30-50/kg) |
| Easy printing | PETG ($25-35/kg) |
| Production parts | PA12 ($60-100/kg) |
| High stiffness | PA6-CF ($80-120/kg) |
| High temperature | PPA-GF ($150-250/kg) |
| >200°C | PEKK, PPS, PPA-GF, PA6-GF |
| 150-200°C | PPA, PA6-GF |
| 100-150°C | PC, PA6-CF, ASA, ABS |
| 80-100°C | PA6, PA12, ABS |
| <80°C | PETG, PETG-CF |
Hotend: 260°C | Bed: 80°C | Chamber: None
Entry-level setup. Limited to low-temp materials.
Hotend: 280°C | Bed: 100°C | Chamber: 60°C
Mid-range. Covers 80% of engineering applications.
Hotend: 350°C+ | Bed: 150°C | Chamber: 100°C
Industrial. Required for high-performance polymers.
Required for: All CF/GF materials
Recommended: Hardened steel, ruby-tipped
Critical for: PA6, PA12, PC, all nylons
Helpful for: PETG, PPA
Required for: CF/GF composites (avoid clogging)
We maintain inventory of all materials covered in this guide. Send us your STL files and requirements for same-day quotes.
Request Quote