Juniper Online

Journal Material Science

ISSN: 2575-856X
Review Article JOJ Material Sci
Volume 8 Issue 4 - April 2024
Copyright © All rights are reserved by Tianxing Cai
DOI: 10.19080/JOJMS.2024.08.5557243

Advancements in Polymer-based 3D
Printing Materials
Tianxing Cai*
Department of Chemical and Biomolecular Engineering, Lamar University, USA
Submitted: March 30, 2024; Published: April 15, 2024
*Corresponding author: Tianxing Cai, Department of Chemical and Biomolecular Engineering, Lamar University, USA

Abstarct

The field of 3D printing has undergone remarkable advancements, fueled by innovations in polymer-based materials. This review paper provides
a comprehensive overview of recent progress in polymer-based 3D printing materials, focusing on their synthesis, properties, and applications.
Beginning with an exploration of traditional polymers such as PLA and ABS, this review delves into emerging materials like photopolymers,
elastomers, and biodegradable polymers. Furthermore, it examines the influence of additives, reinforcements, and nanomaterials on enhancing
the mechanical, thermal, and functional properties of printed parts. Special attention is given to novel techniques such as multi-material printing
and voxel-level control, enabling intricate geometries and tailored material properties. The paper also discusses challenges and future directions
in polymer-based 3D printing, including scalability, recycling, and sustainability. Overall, this review highlights the transformative impact of
polymer materials on advancing the capabilities and applications of 3D printing technology.
Keywords: 3D printing; Thermal resistance; Biocompatibility; Thermoplastics; Photopolymers; Elastomers

Introduction
materials offer distinct advantages and limitations, catering to
As shown in Figure 1, 3D printing, also known as additive
diverse application requirements [7]. For instance, thermoplastics
manufacturing, is a revolutionary technology that enables the
like PLA and ABS are commonly used for their ease of printing
creation of three-dimensional objects layer by layer from digital
and versatility, while photopolymers are preferred for their
designs [1,2]. Unlike traditional subtractive manufacturing
ability to produce highly detailed, smooth-surfaced objects [8].
processes, which involve cutting away material from a solid block,
As 3D printing technology advances, there is a growing demand
3D printing builds objects layer by layer, offering unprecedented
for materials that can meet increasingly stringent performance
design freedom and complexity [3]. This technology has garnered
criteria and enable the production of complex, functional parts
significant attention across various industries due to its ability
[9]. With the rapid evolution of 3D printing technologies, there is a
to produce customized, intricate parts with relatively minimal
growing demand for high-performance polymers that can meet the
material waste and lead times [4]. From aerospace to healthcare,
diverse requirements of additive manufacturing processes. This
3D printing has found applications in prototyping, product
review seeks to provide a comprehensive understanding of the
development, tooling, and even in the production of end-use parts
latest developments in polymer materials tailored for 3D printing
[5,6].
applications. By synthesizing current research and innovations, it
Polymer-based 3D printing has emerged as a revolutionary aims to inform researchers, engineers, and industry professionals
technology with vast potential across various industries, including about the state-of-the-art materials available and the potential
aerospace, automotive, healthcare, and consumer goods. This avenues for further exploration.
review paper aims to explore the recent advancements in polymer-
The purpose of this review is to provide a comprehensive
based 3D printing materials, highlighting their significance,
overview of recent advancements in polymer-based materials
challenges, and future prospects. In the realm of 3D printing,
for 3D printing. Polymer materials, which encompass a wide
materials play a pivotal role in determining the properties,
range of organic compounds, are among the most commonly
performance, and functionality of printed objects [7]. The
used materials in additive manufacturing. This review aims to
choice of material can impact factors such as strength, flexibility,
delve into the synthesis methods, properties, and applications of
durability, thermal resistance, and even biocompatibility. Different

JOJ Material Sci 8(4): [Link].555743 (2024) 001

 Juniper Online Journal Material Science

polymer-based materials, with a focus on the latest developments c) To analyze the applications and potential use cases of
and emerging trends. By examining the progress in polymer- polymer-based 3D printing materials across various industries.
based 3D printing materials, this review seeks to elucidate the
d) To identify the challenges and limitations associated
transformative impact of these materials on the capabilities
with existing materials and propose strategies for overcoming
and applications of 3D printing technology. Additionally, the
them.
review will discuss challenges and future directions in the field,
addressing topics such as scalability, recycling, and sustainability, e) To discuss future directions and emerging trends in
to provide insights into the ongoing evolution of polymer-based the development of polymer materials for 3D printing, such as
3D printing. The objectives of this review paper include: sustainable polymers and functionalized materials.

a) To survey the recent advancements in polymer-based 3D By achieving these objectives, this review paper aims to
printing materials, including novel techniques. contribute to the advancement of polymer-based 3D printing
technologies and facilitate their widespread adoption in diverse
b) To evaluate the performance characteristics of these
industrial sectors.
materials, such as mechanical properties, and biocompatibility.

Figure 1: 3D Printing.

Methodology approaches to provide a comprehensive overview of the subject

matter.
The literature search conducted in this review paper is based
on a systematic approach employed to ensure comprehensive Traditional Polymer-Based Materials
coverage of relevant studies. Multiple academic databases,
Commonly used polymers in 3D printing, such as Polylactic
including but not limited to PubMed, Scopus, IEEE Xplore,
Acid (PLA) and Acrylonitrile Butadiene Styrene (ABS), offer
and Web of Science, were queried using keywords such as
distinct characteristics that make them popular choices in various
“polymer-based 3D printing,” “additive manufacturing materials,”
applications [10,11]. PLA, derived from renewable resources like
and “advanced polymers.” Both peer-reviewed journals and
cornstarch or sugarcane, is biodegradable and emits less harmful
conference proceedings were considered. The selection criteria
fumes during printing compared to ABS, making it environmentally
for relevant studies included their publication date (within the
friendly [10,11]. It boasts good rigidity and strength, making it
last five years to ensure currency), relevance to polymer materials
suitable for prototyping, hobbyist projects, and consumer goods
used in 3D printing processes, and their contribution to advancing
[12,13]. ABS, on the other hand, is known for its durability, impact
the understanding or application of these materials. Additionally,
resistance, and heat tolerance, making it ideal for functional parts
studies were evaluated based on their methodological rigor,
in automotive, electronics, and household appliances [12,13].
experimental design, and the novelty of their findings. Non-
Both PLA and ABS are widely available, affordable, and compatible
English language studies were excluded, and efforts were made
with most desktop 3D printers, making them accessible options
to encompass a diverse range of perspectives and research
for hobbyists and professionals alike [10-13].

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The synthesis methods for polymers used in 3D printing selectively cured layer by layer using UV light [28]. This allows for
typically involve extrusion or resin curing processes [14]. PLA is precise control over curing times and resolutions, resulting in high-
synthesized through the fermentation of plant-based sugars into quality printed parts [28]. Elastomers are synthesized through
lactic acid, which is then polymerized to form long chains of PLA techniques such as addition polymerization or condensation
molecules [15]. ABS, a thermoplastic polymer, is produced through polymerization, resulting in materials with tailored mechanical
a process called emulsion polymerization, where monomers properties, such as varying degrees of elasticity and hardness
like acrylonitrile, butadiene, and styrene are polymerized in an [29]. Biodegradable polymers are often derived from renewable
aqueous medium [16]. Once synthesized, these polymers can be resources such as plant-based sugars or starches and synthesized
further processed into filament or resin forms suitable for 3D through polymerization processes similar to traditional
printing [8,14,15]. polymers, with the added benefit of being environmentally
sustainable [30,31]. The applications and potential advantages of
The properties of PLA and ABS make them versatile materials
photopolymers, elastomers, and biodegradable polymers in 3D
for a wide range of applications in 3D printing [16]. PLA exhibits
printing are vast and diverse [32]. Photopolymers are commonly
good layer adhesion, minimal warping, and a glossy surface finish,
used in industries such as jewelry, dentistry, and prototyping,
making it suitable for aesthetic models, decorative items, and
where intricate details and smooth surface finishes are critical
educational tools [16]. ABS, while more challenging to print due to
[33]. Elastomers find applications in automotive, aerospace, and
its tendency to warp and emit fumes, offers superior mechanical
medical fields, where flexibility, resilience, and impact resistance
properties, chemical resistance, and post-processing capabilities,
are essential [34]. Biodegradable polymers are increasingly being
making it suitable for functional prototypes, mechanical parts, and
utilized in sustainable product design, packaging, and biomedical
engineering applications [17]. Despite their advantages, both PLA
applications, offering the advantage of reducing environmental
and ABS have limitations that need to be considered. PLA is prone
impact and promoting circular economy practices [35]. These
to brittleness and degradation under high temperatures, limiting
specialized polymers offer unique properties and capabilities that
its use in applications requiring heat resistance or load-bearing
extend the possibilities of 3D printing technology, opening up new
capabilities [18]. ABS, while durable and heat-resistant, emits
avenues for innovation and creativity in various industries [36].
potentially harmful fumes during printing, requiring adequate
ventilation or enclosure [19]. Additionally, ABS is more prone to Enhancement Strategies
warping and requires a heated print bed and controlled printing
Additives, reinforcements, and nanomaterials play crucial
environment to mitigate these issues [20]. Understanding the
roles in enhancing the properties of polymers used in 3D printing,
properties, synthesis methods, and advantages and limitations
allowing for the creation of parts with improved mechanical,
of commonly used polymers such as PLA and ABS is essential for
thermal, and functional characteristics [37]. Additives are
optimizing their use in 3D printing applications [11].
substances added to polymer formulations in small quantities to
Emerging Polymer-Based Materials impart specific properties or enhance performance [38]. Common
additives include plasticizers, flame retardants, and UV stabilizers,
Photopolymers, elastomers, and biodegradable polymers
which can improve flexibility, fire resistance, and weathering
represent a diverse range of materials that are increasingly gaining
resistance, respectively [39]. Reinforcements, such as fibers
traction in the field of 3D printing for their unique properties and
(e.g., carbon fiber, glass fiber) or particles (e.g., silica, graphene),
applications [21]. Photopolymers, for instance, are materials that
are incorporated into polymers to increase strength, stiffness,
undergo polymerization when exposed to light, typically ultraviolet
and toughness [40]. Nanomaterials, including nanoparticles and
(UV) light [22]. This process allows for high-resolution printing
nanotubes, offer unique properties such as high surface area-to-
and the creation of detailed, intricate structures with smooth
volume ratio, exceptional strength, and electrical conductivity,
surface finishes [23]. Elastomers, on the other hand, are polymers
enabling further enhancements in polymer performance [41,42].
characterized by their elasticity and flexibility [24]. They can
stretch and return to their original shape, making them suitable The mechanisms of enhancement vary depending on the
for applications requiring rubber-like properties, such as gaskets, type of additive, reinforcement, or nanomaterial used [43]. For
seals, and flexible prototypes [25]. Biodegradable polymers, as instance, fibers and particles act as physical reinforcements
the name suggests, are materials that degrade naturally over time, within the polymer matrix, distributing stress more effectively
making them environmentally friendly alternatives to traditional and preventing crack propagation [44]. This results in improved
polymers derived from fossil fuels [26]. mechanical properties such as higher tensile strength, modulus,
and impact resistance [45,46]. Nanomaterials, on the other hand,
The synthesis methods and characteristics of these specialized
can alter the polymer’s microstructure and interface properties at
polymers vary depending on their composition and intended
the nanoscale, leading to enhancements in thermal conductivity,
applications [27]. Photopolymers are typically synthesized
electrical conductivity, and barrier properties [47,48]. Additionally,
through photopolymerization processes, where liquid resin
additives like plasticizers can increase polymer chain mobility,
formulations containing monomers and photoinitiators are
reducing brittleness and improving flexibility, while flame

How to cite this article: Tianxing C. Advancements in Polymer-based 3D Printing Materials. JOJ Material Sci. 2024; 8(4): 555743.
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retardants can inhibit the spread of flames and smoke generation, such as embedded sensors, conduits, or reinforcement structures
enhancing fire resistance [49,50]. [3,36,66,67]. In healthcare, voxel-level control enables the
fabrication of patient-specific implants and prosthetics with
Examples of enhanced properties and applications resulting
customized mechanical properties and bioactive features,
from the incorporation of additives, reinforcements, and
improving patient outcomes and reducing recovery times
nanomaterials in polymers for 3D printing abound across
[68]. Furthermore, in consumer goods and electronics, these
various industries [51]. Carbon fiber-reinforced polymers (CFRP)
techniques facilitate the creation of personalized products with
offer exceptional strength-to-weight ratios and are used in
enhanced aesthetics, functionality, and performance, driving
aerospace, automotive, and sporting goods applications [52,53].
innovation and competitiveness in the marketplace [69]. Multi-
Nanocomposites, comprising polymers and nanoscale fillers like
material printing and voxel-level control represent powerful
graphene or clay nanoparticles, exhibit improved mechanical
tools for advancing the capabilities of 3D printing technology
properties, thermal stability, and electrical conductivity, making
and unlocking new opportunities for design, manufacturing, and
them suitable for advanced electronics, structural components,
product development across various industries [59].
and biomedical implants [54,55]. Furthermore, functional
additives such as antimicrobial agents and conductive fillers Challenges and Future Directions
enable the production of customized medical devices, electronics
Polymer-based 3D printing has revolutionized manufacturing
housings, and smart textiles with tailored properties [56,57].
by enabling rapid prototyping and customization. However,
The integration of additives, reinforcements, and nanomaterials
scalability remains a significant challenge in this technology
into polymer matrices continues to drive innovation and expand
[8]. Traditional 3D printing methods, such as fused deposition
the capabilities of 3D printing technology across a wide range of
modeling (FDM), suffer from slow printing speeds and limited
applications [8].
build sizes [70,71]. As the demand for larger, more intricate
Advanced Techniques objects grows, scalability issues become increasingly pronounced
[72]. Moreover, maintaining consistent print quality and structural
Multi-material printing and voxel-level control are two
integrity across larger prints presents additional hurdles. These
advanced techniques that have revolutionized the capabilities of
limitations hinder the widespread adoption of polymer-based 3D
3D printing technology, enabling the production of complex, multi-
printing in industrial settings where mass production is essential
functional objects with unprecedented precision and versatility
[73,67].
[58,59]. Multi-material printing allows for the simultaneous
deposition of multiple materials or colors within the same Recycling and sustainability concerns loom large in the realm
printed object, offering designers and engineers the flexibility of polymer-based 3D printing [74]. The process often generates
to incorporate different properties and functionalities into their substantial waste, including unused polymer filaments, support
designs [60,61]. This technique is achieved through the use of dual materials, and failed prints [75,76]. Moreover, the materials
or multi-extruder systems, where each extruder is loaded with a used in 3D printing, such as thermoplastics, can be challenging
different material or color [62]. to recycle efficiently [77]. This results in environmental strain
and contributes to the growing problem of plastic pollution
Voxel-level control, on the other hand, refers to the precise
[77]. Additionally, concerns arise regarding the sustainability of
manipulation of individual volumetric pixels (voxels) within a
feedstock materials, as many polymers utilized in 3D printing are
3D printed object, allowing for localized variations in material
derived from non-renewable resources [78,79].
properties, density, or color [63]. Unlike traditional layer-based
printing, which treats each layer as a uniform slice of material, In response to these challenges, ongoing research efforts focus
voxel-level control enables designers to control the composition on addressing scalability issues and improving the sustainability
and characteristics of each voxel within the object, leading to of polymer-based 3D printing [21,80]. Innovations in printing
unprecedented levels of complexity and functionality [64]. This technologies, such as continuous liquid interface production
technique is made possible through advanced software algorithms (CLIP) and selective laser sintering (SLS), aim to enhance printing
and hardware systems that enable precise deposition and speeds and enable larger-scale production [36,81]. Furthermore,
manipulation of materials at the voxel level, enabling the creation researchers are exploring alternative, eco-friendly materials
of objects with tailored mechanical, thermal, or optical properties derived from renewable sources, such as biodegradable polymers
[65]. and recycled plastics [82]. Additionally, advancements in recycling
technologies, such as filament extrusion systems and closed-loop
The applications and benefits of multi-material printing
recycling processes, offer promising avenues for reducing waste
and voxel-level control are diverse and far-reaching, spanning
and promoting a circular economy within the 3D printing industry
industries such as aerospace, automotive, healthcare, and
[83]. By tackling scalability and sustainability concerns head-on,
consumer goods [58]. In aerospace and automotive applications,
ongoing research endeavors pave the way for a more efficient,
multi-material printing allows for the production of lightweight,
environmentally conscious future for polymer-based 3D printing
high-performance components with integrated functionality,
[84,85].

How to cite this article: Tianxing C. Advancements in Polymer-based 3D Printing Materials. JOJ Material Sci. 2024; 8(4): 555743.
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DOI: 10.19080/JOJMS.2024.08.555743
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Discussion technologies hold promise for unlocking new opportunities

in creating complex, integrated systems with diverse material
In this review paper on “Advancements in Polymer-based 3D
properties, paving the way for more efficient and cost-effective
Printing Materials,” the synthesized findings from the selected
manufacturing solutions. By pursuing these research directions,
studies are interpreted and analyzed to provide insights into the
the field of polymer-based 3D printing can continue to evolve and
current landscape of polymer materials for additive manufacturing.
revolutionize industries while addressing pressing societal and
It involves a comparative analysis of different studies, examining
environmental concerns.
the synthesis methods, properties, and applications of various
polymer-based materials. Beginning with traditional polymers References
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How to cite this article: Tianxing C. Advancements in Polymer-based 3D Printing Materials. JOJ Material Sci. 2024; 8(4): 555743.
008
DOI: 10.19080/JOJMS.2024.08.555743