The Complete Guide to ABS 3D Printing

ABS (acrylonitrile butadiene styrene) is one of the most common and widely used materials for 3D printing. Known for its strength, flexibility and ability to withstand higher temperatures, ABS has become a go-to material for a range of 3D printing applications.

In this comprehensive guide, we’ll cover everything you need to know about successfully 3D printing with ABS filament. We’ll look at the key properties and characteristics of ABS, discuss the applications it’s best suited for, provide tips on how to print ABS models, examine the pros and cons of the material, and compare it to other popular 3D printing filaments like PLA.

What is ABS?

ABS is a common thermoplastic polymer that is widely used across industries like automotive, electronics, toys, medical devices and more. The material is derived from acrylonitrile, butadiene and styrene, the three monomers that make up ABS plastic.

ABS offers a good balance of strength, flexibility, ease of fabrication and cost effectiveness. Parts printed from ABS are known to be durable, rigid and capable of withstanding relatively higher temperatures compared to other common 3D printing materials like PLA.

The most significant properties of ABS for 3D printing include:

• Strength and durability – ABS is a strong, rigid plastic with good tensile strength. This makes it suitable for functional parts that need to withstand physical stresses and strains.
• Flexibility – ABS has good flexibility and impact resistance. Thin-walled parts printed with ABS can bend and flex without breaking or cracking.
• Heat resistance – ABS has a relatively high glass transition temperature of around 105°C, so it can withstand temperatures up to 80°C without warping or deforming. This makes ABS suitable for applications like enclosures for electronics.
• Chemical resistance – ABS offers moderate chemical resistance, meaning it can be used for applications that involve exposure to certain common solvents, oils, acids and salts. It is not resistant to concentrated or strong chemicals.
• Easy post-processing – ABS can be sanded, machined, glued, painted and polished fairly easily compared to many other plastics. This allows for post-print processing and finishing of ABS parts.

Overall, the balance of mechanical strength, flexibility, heat resistance and easy processability make ABS a very versatile material for functional 3D printed parts across a wide range of applications.

Applications of ABS 3D Printing

Thanks to its well-rounded set of properties, ABS has emerged as one of the most widely used materials in 3D printing. Here are some of the popular applications and uses of ABS:

• Prototyping – The ease of working with ABS and ability to produce functional parts makes it a very popular choice for rapid prototyping and iterative design processes. ABS prototypes can be repeatedly tested and refined.
• Mechanical parts – Durable ABS parts with good strength-to-weight ratio are suitable for mechanical parts like gears, machine components, grips, fixtures etc.
• Automotive parts – ABS finds widespread use in automotive interiors and non-critical components. Custom trim pieces, knobs and aesthetic parts can be 3D printed in ABS.
• Electronic enclosures – The heat resistance of ABS makes it well-suited for enclosures for electronics like computers, routers, set-top boxes and printers.
• Toys – Many children’s toys like building blocks, action figures and dolls contain ABS, owing to its durability, safety and vibrant finish. 3D printing facilitates rapid prototyping of toys.
• Tools – ABS is used for creating jigs, fixtures, tool handles and other functional tools due its strength and ability to withstand repeated stresses.
• Education – ABS is popular for 3D printing in schools and colleges thanks to its ease of use and ability to produce detailed, robust models.

For applications that require high strength and temperature resistance beyond the capabilities of ABS, materials like PC, nylon and carbon fiber composites may be more suitable. But for a wide range of functional 3D prints, ABS remains a tried and tested material.

Printing with ABS: Tips and Techniques

While ABS has many advantages, it can also pose some challenges during the 3D printing process compared to simpler materials like PLA. Here are some useful tips to help you succeed when 3D printing with ABS:

1. Use the right extruder temperature

ABS becomes soft and extrudes smoothly in the temperature range of 220°C to 250°C. Set your extruder temperature in this range based on the specific type of ABS filament. Higher temperatures improve layer adhesion but can cause oozing.

2. Use a heated print bed

Heated print beds from 80-110°C are highly recommended for ABS as they prevent warping and improve first layer adhesion. An enclosed printer is also beneficial to stop cooling and shrinkage.

3. Slow down the print speed

Compared to PLA, ABS benefits from slower print speeds of 40-60 mm/s. Slowing down allows layers to bond better and avoids problems like cracking or delamination.

4. Use support structures

ABS can shrink significantly as it cools causing overhangs to curl upwards. Generous use of support structures prevents warping and maintains dimensional accuracy.

5. Avoid drafts & direct cooling

Direct cooling fans can cause rapid shrinkage and warping with ABS. Drafty locations can also cause uneven cooling. Print in enclosed spaces without direct air drafts.

6. Allow proper cooling period

ABS requires slow, even cooling after printing to release residual stresses. Allow printed parts to cool down gradually before removing them from the print bed.

7. Use proper adhesion techniques

ABS warping can lead to delamination from the print bed. Using adhesion aids like glues, tapes, ABS/Acetone slurry helps improve first layer adhesion.

8. Fine-tune extrusion settings

Proper calibration of extrusion multiplier and flow rate is crucial for ABS. Do test prints to dial in the right settings for your specific printer and filament.

With some calibration and the right printing techniques, ABS can produce exceptionally strong and precise 3D printed parts. The effort is well worth the performance payoff for functional components.

Pros and Cons of ABS for 3D Printing

Like any other material, ABS has its own unique set of advantages and disadvantages for 3D printing. Let’s examine some of the key pros and cons of using ABS filament:

Pros:

• Excellent strength and durability for functional parts
• Moderate flexibility and impact resistance
• Maintains stiffness even at higher temperatures
• Easy to smooth, glue, paint and finish post-print
• Capable of high level of detail and dimensional accuracy

Cons:

• Tendency to shrink and warp when cooling due to higher glass transition temperature
• More difficult to 3D print compared to PLA and requires enclosed, heated print bed
• Emits fumes during printing which can be hazardous without ventilation
• Limited chemical resistance compared to advanced filaments like nylon
• Printed parts tend to have faint layer lines compared to the smoother finish of PLA

For most applications, the advantages of ABS outweigh the disadvantages, making it a widely used material for professional 3D printing. The cons can be minimized by using good 3D printer settings and printing in a well-ventilated area.

ABS vs. PLA 3D Printing Filament

PLA and ABS are the two most common and widely used materials in 3D printing. Here is an overview of the key differences between ABS and PLA filaments:

Printing Process

PLA is significantly easier to 3D print compared to ABS. PLA can print on unheated beds, does not require an enclosed chamber, and has little risk of warping. ABS requires higher temps, heated bed, no cooling and controlled cooling to avoid shrinkage.

Strength

ABS is the stronger of the two plastics, offering higher tensile strength and impact resistance. It maintains stiffness at higher temperatures. PLA is still reasonably strong but becomes brittle over time.

Detail

Both can print very smooth and highly detailed models. PLA usually offers a smoother surface finish while ABS can achieve excellent dimensional accuracy if printed properly.

Applications

ABS is used for mechanical parts, product prototypes, tools, enclosures, toys etc. that require good strength and heat resistance. PLA is popular for decorative objects, jewelry, cutlery, wearables etc.

Post Processing

ABS can be sanded, machined, glued and painted relatively easily. PLA can be more problematic to apply finishing techniques to after printing.

Emissions

ABS emits potentially harmful fumes when printed so ventilation is required. PLA does not emit any irritating fumes so it can be used in any environment.

Price

ABS generally costs slightly more than PLA filament. But for professional use, the added benefits of ABS are often worth the small difference in price.

For most functional applications that require the optimum balance of strength, heat resistance and accuracy, ABS remains the top choice over PLA. But for decorative prints and environmentally sensitive applications, PLA can also be a good option.

Conclusion

ABS has become ubiquitous in 3D printing thanks to its versatility and capability to produce strong, lasting parts. With its high impact strength, heat resistance, and easy post-processability, ABS allows functional prototypes and end-use components to be created across industries like automotive, healthcare, electronics and more.

However, printing with ABS poses some challenges like warping and shrinkage that need to be addressed with the right techniques and printer settings. Using an enclosed heated chamber, optimized temperatures, enough supports, controlled cooling and proper bed adhesion allows even novice users to 3D print reliably with ABS filament. The excellent mechanical properties ensure the extra effort is well worthwhile for critical applications.

With a wide range of colors and finishes available, durable and accurate ABS parts can also be made aesthetically pleasing. Although advanced engineered filaments continue to emerge, the balanced performance and cost effectiveness ensure that ABS will continue to play a key role in 3D printing for the foreseeable future.