ABS has been around a long time and for good reason. It&#;s durable, tough and relatively inexpensive. It works well in multiple processes including injection molding, extrusion, 3D printing and especially thermoforming. ABS can be fabricated in its natural color or with a color additive, and thus lends itself to a wide range of opaque applications. So, it&#;s no wonder that ABS is still a popular solution in a wide variety of applications such as toys, device enclosures and automotive parts.
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What many plastics processors may not know, however, is that all ABS is not made the same. ABS made with a process called mass polymerization results in what&#;s sometimes considered a higher grade of engineering resin. That difference can result in substantial advantages in injection molded, extruded or thermoformed component properties in addition to oftentimes a lower cost to manufacture those parts. The enhanced properties offered by this material include:
- Excellent color stability
- Whiter base color
- Purer with less residual monomers, gels and VOCs
- Excellent lot-to-lot consistency
- Wider processing window
Because of these enhanced properties, mass polymerization ABS is widely used in automotive, medical devices, consumer electronics, and high-end extrusion and thermoforming applications, such as with housings and enclosures that require advanced performance and aesthetics.
Emulsion Polymerization vs. Mass Polymerization
Traditionally, ABS has been made with a multi-step emulsion batch reaction process. The result is that there can be significant variability in the material from batch to batch. Perhaps more consequential, the emulsion process requires the use of several processing additives such as emulsifiers and salts. Impurities from the additives typically remain in the finished material in detectable levels, which contributes to the resin&#;s yellowish tint.
Emulsion polymerization uses a batch reaction process requiring emulsifiers and salts that remain in the ABS at detectable levels.
Mass polymerization is a continuous process that uses few additives, resulting in clean, pure ABS material with high consistency.
With mass polymerization, resins are produced in a single, continuous process that uses very few process additives. This yields a much more consistent, purer product with less color. Moreover, because mass polymerization is a continuous process, the material has much less variability in comparison to resins made with batch processes.
This difference is exemplified in the line of MAGNUM&#; ABS resins from Trinseo, a former business of The Dow Chemical Company, and global manufacturer of plastics, latex binders, and synthetic rubber. Using the mass polymerization process, MAGNUM&#; ABS resins are known for greater color stability, thermal stability and for providing a purer ABS resin.
Morphology of Mass vs. Emulsion
Morphology is the result of in situ formation of rubber particles during the SAN matrix polymerization. Pictured below are examples where:
- Light gray background = SAN matrix polymer
- Dark gray spherical particles = rubber particles
- Darker color is the result of a sample pre-treatment process, called staining, and this staining process works specifically on carbon-carbon double covalent bonds that are present in the rubber.
mABS: rubber particles are larger and contain SAN occlusions, therefore the MAGNUM&#; ABS rubber particle morphology is characterized by a high rubber efficiency, which makes it less sensitive to rubber degradation.
eABS: rubber particles are smaller and dense because they are in essence produced in a separate process (rubber latex and GRC production) from the SAN matrix polymerization. This allows a higher control on the rubber particle size and hence the possibility to produce smaller rubber particles, which can be beneficial in case one seeks the highest gloss levels.
Brighter Colors with Less Pigment
The most striking feature when you see MAGNUM&#; ABS in its natural state is how white it is. Because there are fewer impurities, the material is much brighter than conventional ABS, and stays whiter longer, even through multiple regrinds. You can add whitener to lighten conventional ABS but will not be able to reach the level of whiteness that can be achieved with MAGNUM&#; without using any additives.
This low, base color allows the processor to use less pigment yet still achieve a rich color with the end result, particularly with lighter colors. Being able to color parts closer to the target aesthetics with less pigment brings significant cost savings to plastics processors. It&#;s also easy and cost-efficient to use masterbatches, enabling smaller lot production in different colors. Adopting self-coloring allows processors to avoid managing multiple different lots of colors.
Purer Resins Make Better Parts
Low VOCs
A disadvantage of emulsion polymerization is all the residuals that remain in the material. The result is ABS with measurable levels of impurities, VOCs and gels and that can negatively impact downstream processes as well as the final product. As this VOC graph shows, when compared with emulsion ABS (eABS), ABS produced with mass polymerization has substantially lower volatile organic compounds.
Residuals and impurities may intensify the aging process in injection molded parts, losing their color and finish sooner. Higher levels of VOCs raise regulatory concerns, create swirling residue in the extrusion process, and raise the odor level of finished parts, not to mention odor in places where those parts are processed. Ultimately, Pure ABS-type products with less VOCs will cause less odor nuisance for the operators and end users.
Pure ABS with low levels of VOCs will also result in a pure and clean surface after extrusion, which may improve adhesion properties for lamination and gluing or coating. For bending operations, high molecular weight, more efficient use of rubber and more efficient coloring can reduce so-called stress whitening, and allow for sharper bending radius.
Low Gels
Gels, also referred to as unmelts, become a problem in the surface quality of parts, particularly in sheet extrusion. Gel particles do not melt during the extrusion process and can lead to several surface irregularities. In relatively thick sheets, these irregularities may not even be noticeable, but can appear in a secondary process&#;such as in thermoforming&#;creating visible imperfections on the surface of the part. These can be more noticeable if they are located very close to the surface of the sheet (see below), or in cases where a high-gloss acrylic cap layer is co-extruded.
Being more visible after extrusion and even more so after thermoforming, this can be a major issue with products such as automotive interior trim, or with furniture applications where the extruded film is directly laminated/glued on to wooden boards.
The majority of extruded sheets and film contain several layers of ABS applied by means of co-extrusion, with many co-extruded layers as thin as 30 microns. Below demonstrates how gels present in the co-extruded layer are more visible than gels in the core layer.
Pictures on the right side show how the gels cause surface defects (top view of the sheet surface), and the cross sections microscopy pictures show the location and size of the gels.
Because the mass polymerization process never introduces many of these contaminants to begin with, MAGNUM&#; ABS exhibits fewer of these issues. A purer ABS also reduces the likelihood of substance migration from the plastic, which is particularly important in sensitive applications such as with medical devices.
Better Stability In-Process and Over Time
Another benefit of the mass polymerization process is that it yields a material that is more thermally stable. MAGNUM&#;, for example, can be processed at temperatures above 250°C, which&#;combined with its low melt temperature&#;offers an exceptionally wide processing window. Good thermal stability also results in less color shift, which is important to injection molding shops running the same part across different machines.
This image shows how granules change in color after various re-extrusion passes. Pass 1 is the original granule color. The yellow of the eABS is clearly more pronounced than MAGNUM&#;. Further, MAGNUM&#; shows less discoloration over the number of regrind passes, demonstrating higher thermal stability.
The material also exhibits less property shift over time. All ABS resins yellow under solar exposure, but some ABS types yellow less, hence require less UV absorber and save cost.
Compared to emulsion ABS, MAGNUM&#; thermoplastic material has an improved resistance to UV light such that less UV additive is needed to stabilize molded, extruded and thermoformed parts. In accelerated QUV-A weathering tests, the material demonstrated a 50 percent slower aging rate than conventional ABS. This means parts retain their color and surface appearance longer, which is critical for materials exposed to sunlight.
This graph shows the evolution of the delta E value when exposed to a QUV-A accelerated weathering test. The delta E value is a numerical value that expresses the total color change compared to the original color before the test. The emulsion ABS color ages twice as fast as the MAGNUM&#; ABS. That means, in theory, that MAGNUM&#; ABS needs about half the amount of UV absorber compared to eABS for indoor exposure conditions.
Optimizing ABS for Edgebanding
MAGNUM&#; ABS resins also offer an excellent balance of features such as toughness, extrudability and surface aesthetics required by demanding standards in the furniture industry. Since ABS is an ideal product for several opaque applications, this makes it a great candidate for edgebanding.
In particular, MAGNUM&#; ABS Resins feature the key performance properties required for edgebanding&#;strength of durability and impact, stain, and moisture resistance. Because these resins are produced without the use of chlorinated ignition resistant additives, the result is an environmentally-friendly alternative throughout the material&#;s lifecycle including incineration that has made Trinseo&#;s ABS a material of choice.
These resins&#; material formulation provide unique low and consistent base color alongside high color stability after processing, allowing for easy color tuning for edgebanding producers. This is vital for converters, who oftentimes produce several hundred combinations of color and embossing, often in small order sizes.
Edgebanding requires an extruded process that goes through lamination before being sent out to end product users.
Here are a few other examples of ABS extrusion applications.
Extrusion Channel to Market
ABS extrusion has two main segments: sheet and edge bands (including profiles, wide vs. narrow). In sheet we find ABS/PMMA co-extruded films for furniture applications, for example high-gloss kitchen furniture panels; vehicle exterior parts (i.e. roof and wheel arches tractor, sleep compartment motor home, roof boxes for cars, decorative panels for automotive interior); sanitary (shower trays or bath tubs) luggage cases and doors. The majority of these applications are ABS/PMMA co-extruded sheet for thermoforming. Edge bands for furniture, and profiles for white goods, however, are made of mono-extruded ABS.Roughly 90% of all extruded sheet is thermoformed.
The sheet extruder, in some cases, does not supply directly to the brand owner but to the thermoformer. The transformation from granules to end product goes through two distinct different processes, each that have their own ABS resin attributes: the primary process first is sheet extrusion and the second is thermoforming.
ABS Sheet Extrusion Channel to Market:
- Trinseo Performance Plastics
- Sheet Extrusion (Primary Process)
- Thermoforming (Secondary Process)
- Band Owner (End Product)
- Retailers/End users
The Bottom Line
ABS produced with mass polymerization technology has significant visible advantages. While mass ABS is certainly a popular option, this isn&#;t to say that it is the ideal choice in every scenario. Emulsion ABS has historically performed better for plating applications, for example. While MAGNUM&#; ABS can be supplied in a wide range of gloss levels, applications demanding the highest gloss levels may benefit from the emulsion method.
MAGNUM&#; ABS inherently has a low base color and is very consistent whereas emulsion ABS is produced in a smaller batch process and is expected to be less consistent from lot-to-lot. However, if your need is for smaller custom lots of material, emulsion ABS may be a consideration.
Who is Trinseo?
While well known in the automotive industry, Trinseo is continuing to grow as a strong presence in several other markets. Trinseo was formed in by combining four businesses of The Dow Chemical Company:
- Polycarbonate and Compounds & Blends
- Paper and Carpet Latex
- Synthetic Rubber
- Styrenics (polystyrene, ABS/SAN resins)
Today the company has over 2,000 employees in 25 countries with a global footprint that includes 15 manufacturing sites and 10 R&D labs across the world.
Learn more about MAGNUM&#; ABS resins and Trinseo plastics products.
by 3devo on Jul 10, 11:00:00 AM
In the exciting world of 3D printing, one of the first decisions you&#;ll need to make is choosing the right filament. This decision can be daunting for newcomers and seasoned enthusiasts alike, given the vast array of filament types available. However, two filaments that stand out in popularity are ABS (Acrylonitrile Butadiene Styrene) and PLA (Polylactic Acid). These two materials have distinct properties, making them suitable for different applications. This guide will give a 3D printing filament comparison, helping you understand the key differences, benefits, and applications of ABS and PLA filaments, so you can make an informed decision for your 3D printing projects.
Understanding 3D Printing Filament
Before diving into the specifics of ABS and PLA, it's essential to understand the fundamental role of 3D printing filament. 3D printers don't just emit models right there on the spot; some material must be used to make a model colorful, strong, heavy, or whatever else you may need it for. This material is called the filament, and it is the ingredient used in your gourmet 3D-printed sandwich - 3D printing filament properties are fundamental when considering the application of your print. Its formal definition is a slender threadlike object or fiber from animal or plant-like structures. However, in 3D printing, it relates to the cable-like material that gets placed in a coil (or spool) onto a 3D printer. You can buy filament from stores, online, or even create your own with a Filament Extruder.
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The Battle of the Titans: ABS vs PLA
There are several types of filaments available today, with new ones probably being released even as you read this article. However, the majority of these materials may not be relevant to your needs. Therefore, this guide will compare the two most popular thermoplastics, ABS and PLA, and understand why they are so appealing.
In the exciting world of 3D printing, ABS and PLA are the two most popular materials for a reason. They are relatively easy to work with, widely available, and suitable for a variety of applications.
ABS: The Robust Veteran
ABS, the granddaddy of filaments, is renowned for its strong build and slight flexibility. This makes it suitable for a variety of objects, from tools to toys, cases to fan blades. Its overall ease of extrusion, higher temperature resistance, improved flexibility, and strength make it a favored material for engineers and professional applications.
Pros of ABS:
- Very Sturdy and Hard: Suitable for machine parts and increased lifespan.
- More Flexible: Easier to work with for parts that need a bit of give.
- Higher Melting Point: Suitable for objects that need to cope with temperatures over 60ºC.
Cons of ABS:
- More Difficult to Print: Requires a heatbed and is prone to cracking if cooled too quickly.
- Not Food Safe: Not suitable for use with food.
- Odor: Produces a hot, burning plastic smell during printing.
PLA: The Environmentally-Friendly Choice
PLA, on the other hand, is derived from corn and other renewable starches, making it a biodegradable and environmentally friendly option. Its glossy appearance, large color variety, and different transparency choices make it an ideal choice for hobbyists and printing enthusiasts.
Pros of PLA:
- Environmentally Friendly: Biodegradable and made from renewable resources.
- Ease of Printing: Can be printed on a cold surface, has a shinier and smoother appearance, and allows for higher 3D printer speed.
- More Rigid: Suitable for applications requiring more rigid features and detail.
Cons of PLA:
- Can Deform Due to Heat: Not suitable for objects used in temperatures greater than 60ºC.
- Limited Flexibility: PLA is more rigid and brittle than ABS, making it less suitable for flexible parts.
- Color Alteration: The bent area of PLA can turn white, which might not be aesthetically pleasing for some applications.
Material Characteristics
It is crucial to understand the characteristics of ABS and PLA to choose the right material for your project. ABS has a higher glass transition temperature, which means it can withstand higher temperatures before it begins to deform. This characteristic makes it suitable for objects that will be exposed to high temperatures. However, PLA has a lower glass transition temperature, which means it will start to deform at lower temperatures than ABS.
On the other hand, PLA has a higher tensile strength than ABS, making it stronger and more rigid. However, this rigidity can also make it more brittle and less flexible than ABS. ABS has better ductility, which means it can deform under stress without breaking. This property makes ABS a better choice for objects under mechanical stress or requiring flexibility.
Printing Parameters
The printing parameters for ABS and PLA are also different. ABS requires a higher printing temperature compared to PLA. It typically prints at around 210-250°C, whereas PLA prints at around 160-220°C. The bed temperature for ABS also needs to be higher, usually around 100-110°C, to prevent warping, whereas PLA can be printed on a bed heated to around 50-60°C. Additionally, ABS tends to shrink as it cools, which can lead to warping or layer separation if not properly managed. PLA, on the other hand, has minimal shrinkage and is less prone to warping.
Moreover, ABS produces fumes during printing that can be unpleasant and may require proper ventilation, while PLA emits a sweet, corn-like smell and does not produce toxic fumes.
Recycling and Environmental Impact
PLA is biodegradable and compostable, making it an environmentally friendly option. However, it is important to note that PLA requires specific conditions to biodegrade fully, and it may not break down in a regular compost pile or landfill. ABS, on the other hand, is not biodegradable but can be recycled. However, the recycling process for ABS can be complex and is not widely available.
Moreover, the production of PLA consumes less energy and produces fewer greenhouse gas emissions compared to ABS, making it a more sustainable option overall.
ABS vs PLA: A Head-to-Head Comparison
ABS
PLA
Full Name
Acrylonitrile Butadiene Styrene
Polylactic Acid or Polylactide
Composition
Petroleum
Plant-based (Plant Starch)
Properties
Durable, Strong, Slightly Flexible, Heat Resistant
Tough, Strong, Rigid
Extruder Temperature
210-250°C (410-482F)
160-220°C (320-428F)
Environmental Impact
Non-biodegradable, recyclable
Biodegradable, compostable
Price
Relatively cheap (more expensive than PLA)
Cheap
Smell
Hot Burning Plastic
Sweet Cooking-Oil Like Smell
Post-processing
Easy Sanding, Easy Gluing, Easily Soluble in Acetone
Sanding Possible, Limited Gluing
Pros and Cons ABS VS PLA Summary
We can&#;t tell you which one you should use, as we don&#;t know what you are going to be printing. But we can help you lean in the right direction by providing you with the pros and cons for each one. If you really enjoy the pros and can deal with the cons, then that filament is your answer.
ABS Pros:
ABS Cons:
PLA Pros:
PLA Cons:
- Can deform due to heat
- Less sturdy, more brittle
- Bent areas turn white
- Not suitable for use with food
- Lower melting point
When to Use Which Filament
Now that you are aware of the details of each type of filament and how it makes it either good or bad to use for certain conditions, it's time to decide when you should use ABS or PLA.
ABS
ABS is your go-to filament if the object you are printing is likely to be dropped often, like tool parts, or if the object needs to withstand temperatures over 60ºC. However, you should steer clear of ABS if you don&#;t have a heat bed, as this is essential for printing with ABS. Additionally, if you plan to print large objects in a place where there might be wind or changes in temperature, ABS might not be the best choice as it is prone to cracking and splitting in these conditions. Finally, if the place where you are printing doesn&#;t have good ventilation, it is better to avoid ABS as the smell produced during printing can get quite unpleasant.
PLA
PLA is the filament of choice for 3D printing enthusiasts and is suitable for a wide range of applications. It can sometimes be used in outdoor areas and is perfect for gifts and prototypes. However, PLA is not ideal for objects that might be dropped often as it is too brittle for tool handles. Also, if the object you are printing will be used in temperatures greater than 60ºC, it is better to avoid PLA as sagging can occur.
Cost Considerations
Cost is another essential factor to consider when choosing between ABS and PLA. The price of filament can vary based on the brand, quality, and the supplier. Generally, PLA is slightly more expensive than ABS because it is made from renewable resources, whereas ABS is made from petroleum. As of this article, the cost for ABS ranges from $14-60 per kg (&#;11.90 - 51/&#;kg), while PLA ranges from $19-75 per kg (&#;16.15 - 63.75/&#;kg). However, it is crucial to note that the price of filament does not always correlate with its quality. A more economical and empowering solution is to create your own filament using a Filament Extruder like the ones offered by 3devo. Our filament makers allow you to produce your own high-quality filament at a fraction of the cost of pre-made filaments, giving you greater control over the quality, color, and material properties. While purchasing filament from reputable suppliers is always an option, we highly recommend creating your own filament to maximize cost savings, customization, and environmental considerations.
Conclusion
Choosing between ABS and PLA involves weighing the pros and cons of each material against your specific needs and applications. ABS offers durability and flexibility, making it ideal for objects requiring strength and resilience. PLA, an eco-friendly alternative, offers a glossy finish and is well-suited for decorative items and prototypes. Before making a final decision, it is wise to consider each material's strengths and limitations and test small quantities of both. Additionally, producing your own filament using a Filament Maker, like those provided by 3devo, can offer cost savings, customization, and environmental benefits. This approach allows you to have greater control over the quality, color, and material properties, enabling you to optimize your 3D printing projects further.
FAQ
How do PLA and ABS react to exposure to UV light or outdoor elements?
PLA tends to degrade faster when exposed to UV light or outdoor elements as it is biodegradable. ABS, on the other hand, is more resistant to UV light and outdoor elements, but over time, it can also degrade, causing discoloration and loss of strength.
What are the most common post-processing techniques for PLA and ABS, and how do they affect the material properties?
Common post-processing techniques for PLA and ABS include sanding, painting, and acetone vapor smoothing (for ABS only). Sanding can help to smooth the surface but may reduce the part's dimensional accuracy. Painting can improve the aesthetic appearance and may offer some additional UV resistance. Acetone vapor smoothing for ABS can greatly improve surface finish but may slightly reduce the part's dimensional accuracy and strength.
How do humidity and storage conditions affect PLA and ABS filament before and after printing?
PLA is hygroscopic, meaning it absorbs moisture from the air, which can lead to printing issues such as nozzle clogging and poor layer adhesion. It is essential to store PLA in a dry, cool place, preferably with a desiccant. ABS is less sensitive to moisture but should still be stored properly to ensure optimal printing performance.
What are the environmental impacts of producing PLA and ABS filament?
PLA is made from renewable resources such as cornstarch or sugarcane and is biodegradable under industrial composting conditions. However, the production process still has environmental impacts, such as the use of genetically modified crops and the energy required for production. ABS is made from petroleum-based resources and is not biodegradable, making it less environmentally friendly than PLA.
Are there any common challenges in producing PLA or ABS filament?
Producing PLA or ABS filament using a filament maker can present challenges like maintaining a consistent diameter and ensuring the filament is free of bubbles or voids. Temperature control is critical, as too high a temperature can degrade the material, and too low a temperature can lead to incomplete melting and inconsistent filament.
What are some emerging trends or new developments in PLA and ABS materials for 3D printing?
There are continuous developments in PLA and ABS materials to improve their properties. For example, there are now PLA filaments with enhanced toughness and heat resistance, making them suitable for more functional applications. Similarly, ABS filaments have improved warping resistance and better surface finish. There are also filaments made from recycled PLA and ABS, contributing to a more sustainable 3D printing ecosystem.
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