Since the 1980s, 3D printing – also known as additive manufacturing – has revolutionised the way products are made. Initially used for rapid prototyping, it has evolved into a powerful tool for full-scale production. Over the past few decades, 3D printing has enabled faster development cycles, greater design flexibility and more efficient manufacturing processes.
A key advancement in 3D printing is the continuous development of new and enhanced materials, expanding the potential of additive manufacturing across a wide range of industries.
Over the past few years, we’ve invested heavily in material innovation for our in-house 3D printers – broadening our portfolio to include high-performance materials that elevate both functionality and durability.
We explore what performance materials mean in the context of 3D printing and how they enable applications across industries that demand exceptional durability – such as environments with extreme temperatures or strict regulatory requirements.
What are performance materials?
Performance materials in 3D printing are advanced polymers and composites engineered to meet specific functional, safety, or regulatory requirements. They are ideal for demanding environments, such as healthcare, aerospace and electronics where regulations and safety are high, by offering enhanced properties such as flame retardancy, chemical resistance, high strength, or biocompatibility.
Unlike standard materials they enable the production of durable, compliant and high-quality parts, often bridging the gap between prototyping and full-scale manufacturing. ABS (Acrylonitrile Butadiene Styrene), for example, is a strong, tough material but can be a challenging material to print. It is now becoming more ubiquitous as machine manufacturers incorporate features that make it much easier to manufacture.
Standard materials like PLA (Polylactic Acid) and PETG (Polyethylene Terephthalate Glycol) are easy to print and cost-effective but lack the strength and heat resistance of performance materials. These advanced options offer superior durability and thermal stability, making them ideal for industrial and engineering applications, though they require more specialised equipment.
Key types of performance materials
Performance materials in 3D printing are engineered for demanding applications where standard materials like PLA or PETG fall short. These include:
- Flame-retardant polymers (e.g., ABS-FR, UL94 V0-rated materials)
- High-temperature materials (e.g., PEEK, PEI/Ultem)
- ESD-safe materials for electronics
- Biocompatible materials for medical applications
- Carbon-fibre or glass-fibre reinforced composites for strength and stiffness
- Flexible and elastomeric materials (e.g., TPU (Thermoplastic Polyurethane))
Why use performance materials?
In industries where safety, compliance and reliability are crucial, performance materials play a vital role. Unlike standard filaments like PLA or PETG, performance-grade materials such as Nylon, Polycarbonate (PC), PEEK (Polyether ether ketone), and Carbon Fiber composites are engineered to meet stringent industry standards – including RoHS (Restriction of Hazardous Substances) and UL94 (flammability rating).
Designed to withstand harsh environments, these performance materials offer superior mechanical strength, thermal resistance and chemical durability. This makes them ideal for functional prototyping, where parts must perform under real-world conditions and for end-use components that require long-term reliability.
Applications across industries
Performance 3D printing materials are transforming a wide range of industries by enabling the production of durable, compliance and high-performance parts for both prototyping and end-use applications. These include:
- Healthcare – Biocompatible implants, diagnostic tools
- Aerospace & Automotive – Lightweight, heat-resistant components
- Electronics – ESD-safe housings, flame-retardant enclosures
- Industrial – Complex bespoke components, part consolidation, Custom tooling, jigs and fixtures
Challenges and considerations
While performance materials offer significant advantages, they also come with unique challenges that must be carefully considered:
- Performance filaments often need specialised printers with high-temp nozzles, heated beds and enclosed chambers for stable, successful prints.
- These materials are more expensive than standard filaments and can be harder to source, especially for certified or niche applications.
- Printed parts may require extra post-processing steps like annealing, support removal, or surface finishing to meet functional or visual standards.
- Industrial use often demands certified materials and thorough testing to meet safety and regulatory requirements.
Performance materials at the 3M BIC
We now offer 3D printing capabilities in over 40 materials, including a range of high-performance options such as:
- Fibre reinforced materials – from PETG-CF to ABS-GF and Nylon -CF
- TPU (Thermoplastic Polyurethane)
- Polypropylene
- Polycarbonate
- High temp resin (up to 230oC, Heat deflection temperature)
- Flame retardant resins
- A range of bio-compatible resins (flexible, clear, durable & white)
- Silicone resin
- Nylon PA12
- Stainless steel
- Titanium
You can find out more about our materials and 3D printers here.
Performance materials are certainly pushing the boundaries of 3D printing and continually being developed with new and novel characteristics. Whether it’s a high-temperature application, exposure to chemicals, or mechanical stress, performance materials ensure that printed parts maintain integrity and safety. While they may require more advanced printers and controlled settings, the trade-off is worth it for industries that demand precision, compliance and durability.
Get in touch today to arrange a free consultation to discover which high-performance material is best suited for your project.
