Heat-Resistant 3D Printing Materials Guide: Compare Processes, Materials, and Applications

FDM 3D printing is well-suited for basic proof-of-concept models, as well as quick and low-cost prototyping of simple parts, such as parts that might typically be machined. It can be fast for simple designs and because many people think of FDM technology and the ‘hot glue gun’ process when they visualize 3D printing, it can be an easy introduction to 3D printing. 

However, FDM has the lowest resolution and accuracy when compared to SLA or SLS and is not the best option for printing complex designs or parts with intricate features. Most professional and industrial FDM 3D printers use soluble supports to mitigate some of these issues and offer a wider range of engineering thermoplastics, but they also come at a steep price.

There are a wide range of FDM printers available for fabricating heat-resistant 3D printed parts. Many printers have open platforms as well, so that customers can print with multiple types of filaments from different manufacturers. 

The main requirement for FDM 3D printing heat-resistant parts is making sure that the printer extruder and print bed can achieve the higher temperature settings necessary to melt and extrude heat-resistant filaments and to stabilize the parts during the printing process. A closed build chamber is recommended to maintain a consistent and high temperature during printing. Filaments that offer the highest heat resistance, like PEEK or ULTEM, are only compatible with specialized industrial FDM printers.

Because these materials are designed to resist deformation at higher temperatures, melting and extruding them also often present difficulties and can create inconsistent prints, nozzle jams, or other issues.

The two most common materials for FDM printing are PLA and ABS. Of the two, ABS offers higher heat resistance. There are also other more heat-resistant filaments available, however, these are often harder to print with or require specialized industrial 3D printers.

PLA

PLA is the most common plastic material for filament 3D printers — it’s low cost,  has a very simple workflow, and comes in many colors, making it appealing to the hobbyist and K-12 education market. Standard PLA has a relatively low heat resistance, with an HDT of around 50 ºC at 0.45MPa. Therefore, for those looking to preserve the ease of use while being able to quickly and easily print heat-resistant PLA parts, many manufacturers offer a PLA material with additives that improve its heat resistance. Additionally, some workflows recommend an annealing step — meaning finished parts are reheated to further crystallize their structures and prevent creep or slow deformation when under strain.

ABS

ABS is the most common FDM 3D printing filament for engineering and other professional applications. It produces parts that are strong and impact-resistant. With an HDT of 90 ºC at 0.45MPa, it has better heat resistance than other common filament types like PLA or PETG. ABS parts are ideal for rapid prototyping applications and in education; the low cost and accessible workflow make it a popular choice for quick prints.

Polycarbonate (PC)

Polycarbonate materials, though known for their high tensile strength and temperature resistance, are typically difficult to 3D print because they expand when exposed to heat, and 3D printed parts can crack or malfunction. FDM 3D printer manufacturers often get around this by creating polycarbonate composites with additives that increase their adhesive ability. Some heat-resistant polycarbonate composite filaments can achieve HDTs of up to 110 ºC to 140 ºC at 0.45MPa, but require high temperatures for the print bed and extrusion nozzle, which can limit the types of printers available. 

PEEK

PEEK or PEEK composite filaments offer the highest heat resistance for FDM 3D printing. These filaments, when combined with a material such as carbon fiber, as is the case with PEEK-CF, a carbon fiber PEEK composite, can reach up to 260 ºC before deforming under strain, making them ideal for quick prototyping of electrical connectors, outdoor products, or jigs and fixtures around molding applications and processes. The material is highly chemical resistant, friction resistant, and can be machined once in a solid form post-printing. PEEK’s heat resistant properties make it difficult to melt and extrude smoothly, and many users report that reliability and consistency with PEEK are harder to achieve. PEEK filaments are only compatible with a a few indsutrial FDM printers. To ensure good results, printers must have an extruder that can reach 400 °C, a chamber that can be heated to 120 °C, and a build plate that can heat to 230 °C. PEEK is also subsitantially more expensive than other filaments. 

ULTEM (PEI)

ULTEM is another name for polyetherimide (PEI), a high-performance thermoplastic frequently used in FDM 3D printing because of its heat resistance and strength. With an HDT of around 150 °C at 0.45MPa and a high tensile strength, it is a worthy, and less expensive, replacement for PEEK in a variety of applications. ULTEM is more easily printed than PEEK, but still requires a high heat extruder — around 360 °C — to achieve good results, therefore only a limited range of FDM printers are suited for printing ULTEM filament.

Resin 3D printers are ideal for creating high-quality parts with smooth surface finishes, tight tolerances, and a wide range of material properties. 

Because resin printers cure liquid plastics with a light source, the layers are chemically bonded to each other in all directions, meaning the parts have isotropic mechanical properties, and aren’t prone to shearing along a particular axis like FDM parts are. This means resin 3D printed parts printed with heat-resistant resins can be relied upon for seals and gaskets, electrical connectors that need to mate with other components, or even automotive, aerospace, and energy utility applications where high temperatures are the standard environment. 

The SLA process also lends itself to smooth surface finishes, few or nearly invisible layer lines, and a high degree of accuracy and precision. Heat-resistant resins are ideal for functional prototypes, manufacturing aids, and end-use parts in maintenance and repair operations (MRO) applications where the end-use environment might be hot. 

Material availability for resin 3D printing is highly dependent on the type of printer. Unlike with FDM 3D printing, where common types of plastic are available for different types of printers, SLA manufacturers often formulate and create their own, proprietary materials.

Formlabs offers over 40 high-performance resins for its line of desktop and large-format resin 3D printers with a diverse range of material properties. Certain resins are specifically designed for heat-resistance, such as High Temp Resin, while others are designed for other material properties, such as tensile strength, but achieve a high HDT as well.

SLA 3D printing delivers smooth, end-use quality parts that can perform in a variety of different environments. Formlabs has developed several high-temperature resistant resins specifically for customers working in extreme environments, in addition to creating several exceptionally strong resins that are also heat-resistant. 

When choosing a resin printer for a heat-resistant 3D printing workflow, it’s important to delineate which mechanical properties are important in addition to HDT. For instance, if your parts will have an end-use operating environment of 200 ºC, that’s the first mechanical property to evaluate. If they only have an end-use operating environment of 150 ºC, you will have more options to choose from, and can then evaluate the printer based on other materials available, surface finish, ease of use, and price.

Clear Resin

Resin 3D printing offers the unique possibility to create truly transparent 3D printed parts. A standard material designed for strength and durability, Clear Resin has good enough heat-resistance that it can be used for higher heat applications such as hot air or gas ducting. With an HDT of 73 °C at 0.45 MPa, this general purpose material is excellent for functional prototyping. Clear Resin can be used for lower temperature molding applications, such as polyurethane molding, as mold temperatures tend to only reach about 60 °C.

Tough 2000 Resin

For prototyping strong, stiff, and sturdy parts that should not bend easily, Tough 2000 Resin is an excellent choice. It can be used for jigs and fixtures requiring minimal deflection, due to its close simulation of the strength and stiffness of ABS.

High Temp Resin 

For high-temperature applications requiring the smooth surface finish and optimized material properties of SLA resins, High Temp Resin is a great fit. It is a purpose-built resin designed for high-heat resistance. With an HDT of 238 °C at 0.45 MPa, the highest among Formlabs resins, High Temp Resin is ideal for applications like functional prototyping of high-heat consumer electronics, hot air, gas, and fluid flow, and molds and inserts.  

Flame Retardant Resin 

Specially-designed to be self-extinguishing and halogen-free, Flame Retardant Resin is an SLA material with a UL 94 V-0 certification and favorable flame, smoke, and toxicity (FST) ratings. It is ideal for printing flame retardant, heat resistant, stiff, and creep-resistant parts that will perform well long-term in indoor and industrial environments with high temperatures or ignition sources. It has an HDT of 111 ºC at 0.45 MPa.

Rigid 10K Resin 

Rigid 10K Resin is highly glass-filled material that is strong, stiff, and resistant to deformation under a variety of forces, pressures, and torques. It offers a very high heat resistance with an HDT of 238 °C at 0.45 MPa. It is ideal for short-run injection mold masters and inserts, aerodynamic test models, and fluid-exposed jigs, fixtures, and connectors.

Silicone 40A Resin

Combining the high performance of silicone and the design freedom of 3D printing to create highly functional silicone parts with excellent chemical and heat resistance (up to 125 °C), Silicone 40A Resin is the first accessible 100% silicone 3D printing resin. It can achieve fine features as small as 0.3 mm, and complex geometries that are not possible with traditional methods.

Alumina 4N Resin

The only accessible, high-performance technical ceramic, Alumina 4N Resin enables new 3D printing applications for extreme environments. Though printing with it does require extra equipment for a true ceramic burnout, once fully completed, Alumina 4N Resin parts have a maximum working temperature of 1500 °C. Using this material opens up new applications in industrial casting, molding, and even in specialty applications such as nuclear waste and liquid metals handling.

_{Note: Heat resistance properties differ as no metric is applicable to all materials. The table shows thermal stability for Silicone 40A Resin, maximum working temperature for Alumina 4N Resin, and heat deflection temperature @ 0.45 MPa for all other materials.}

SLS 3D printers excel at producing end-use quality parts that have the strength and durability of injection molded goods. The self-supporting nature of the powder bed makes it possible to print parts without supports, enabling quicker post-processing and the possibility of shapes that would be difficult to print with SLA or FDM technology. 

SLS ecosystems can often recycle powder, leading to higher efficiency and lower cost per part. SLS printers frequently have larger build volumes than other technologies and the self-supporting nature of the technology allows for printing larger batches of parts, which make it possible to accomplish low- to mid-volume production volumes. The high heat that is used to sinter SLS materials means that finished parts can achieve high temperature resistance.

SLS printers can often be more expensive than FDM or SLA technologies, though accessible options like the Formlabs Fuse Series enable in-house production of heat resistant SLS parts at an affordable price. Printed parts also have a slightly rough surface finish, however, this can be easily improved using post-processing solutions.

SLS 3D printing powders are naturally heat-resistant, so the options for choosing an SLS printer aren't too limited if the application requires a higher HDT. The go-to material for SLS 3D printing is nylon, while most SLS printer manufacturers offer a range of familiar thermoplastic powders. Because the materials are often common across manufacturers, other features, such as build volume, price, workflow, and infrastructure requirements are typically the differentiating factors when choosing between brands of SLS 3D printer. 

The Formlabs Fuse Series introduced an accessible, affordable, benchtop-sized solution for both high-quality prototyping and end-use production. With a range of industry-standard powders available, such as nylon 12, nylon 11, nylon composites, TPU, and polypropylene, it offer many options for producing heat-resistant parts.

The most common material for selective laser sintering is nylon, a highly capable engineering thermoplastic that is resistant to UV, light, heat, moisture, solvents, temperature, and water. It is ideal for complex assemblies and durable parts with high environmental stability. It is available in multiple variants and in composite forms, each tailored to different applications. Other popular SLS materials include the ductile polypropylene (PP) and the flexible TPU, both offering good heat-resistant properties.

Nylon 12 Powder

Balancing strength and detail, Nylon 12 Powder is a highly capable material for both functional prototyping and end-use production of complex assemblies and durable parts with high environmental stability. It offers an HDT of 171 °C at 0.45 MPa, making it one of the best general purpose materials for high-temperature applications.

Nylon 12 GF Powder

Nylon 12 GF Powder is a glass-filled material with enhanced stiffness and heat resistance under strain to endure demanding manufacturing conditions. Ideal for applications where structural rigidity and thermal stability are critical, such as high-performance functional prototypes or robust end-use parts that need to maintain dimensional accuracy.

Nylon 11 Powder

Nylon 11 Powder is a ductile and robust material with an HDT of 182 °C at 0.45 MPa. It is suitable for 3D printing heat-resistant parts that need to bend or take impact, for functional prototyping and small batch production.

Nylon 11 CF Powder

Nylon 11 CF Powder is a carbon fiber reinforced powder that is ideal for stiff, strong, lightweight parts that can endure high heat for long-term use. It has an HDT of 188 °C at 0.45 MPa, making it Formlabs' most temperature resistant SLS powder. It is ideal for high-heat applications that require strength and stiffness, such as replacement and spare alternatives to metal parts.

Polypropylene Powder

Polypropylene Powder is a genuine polypropylene (PP) that offers high ductility, allowing for repeated bending and flexing while ensuring durability, without the need for inert atmospheric control. With an HDT of 113 °C at 0.45 MPa, it has a bit lower heat resistance than nylon, but can still produce works-like prototypes and durable end-use parts that are chemically resistant, weldable, and watertight.

TPU 90A Powder

SLS 3D printers can also create flexible TPU parts with unmatched design freedom and ease. Combining the temperature resistance, high tear strength, and elongation at break of rubber materials with the versatility of SLS 3D printing, TPU 90A Powder is ideal for producing flexible, skin-safe prototypes and end-use parts that withstand the demands of everyday use.

_{Note: Heat resistance properties differ as no metric is applicable to all materials. The table shows Vicat softening point for TPU 90A Powder and heat deflection temperature @ 0.45 MPa for all other materials.}

Metal 3D printing is valued for its ability to combine the strength, durability, and heat resistance of metal parts with the design freedom of 3D printing. Metal 3D printed parts are sought after for use in the aerospace and automotive industries, where lightweighting parts through generative design can deliver high performance without added weight; something that wouldn’t be possible through traditional machining methods of metal fabrication. 

The high power inputs required to manipulate, melt, and/or extrude metal or metal-composite materials mean that these metal printers are often extremely expensive — one model deemed ‘entry-level’ costs upwards of $80,000. Industry leaders in the metal 3D printing space offer machines commonly priced at half a million dollars or more, and require extensive infrastructure to support their processes, like separate rooms and dedicated operators.

There are fewer metal 3D printer manufacturers than for plastic 3D printing, but the number is growing as the demand increases for workflows that can deliver both the strength and industry-familiar materials of metal parts and the design possibilities of 3D printing.

These manufacturers are grouped into roughly two technologies: extrusion and powder bed fusion. Metal FDM printers work similarly to traditional FDM printers, but use extrude metal rods held together by polymer binders. The finished “green” parts are then sintered in a furnace to remove the binder.  Selective laser melting (SLM) and direct metal laser sintering (DMLS) metal 3D printers work similarly to SLS printers, but instead of fusing polymer powders, they fuse metal powder particles together layer by layer using a laser. 

One of the strengths of metal 3D printing is that each material is familiar to customers — whether they start as rods that are melted and bound together, or powder that is sintered into form, metal materials like steel or aluminum are easy recognizable and understood by potential 3D printing users. The most popular materials are the same metals that are found already in aerospace, automotive, industrial, agricultural, and utilities industries. 

Titanium

Titanium is a highly temperature-resistant metal and one of the most commonly used alloys in 3D printing. It is resistant to corrosion and has light weight in relation to its strength.

Stainless Steel

Stainless steel is a well-known material that is used in many easily visible architecture, design, automotive, and aerospace applications. 3D printing stainless steel can be useful for one-off replacement parts for applications like manufacturing, where traditional fabrication methods might take weeks, or for remote locations such as naval ships printing parts while at sea. The melt point of stainless steel changes based on the exact formulation of the material, which is a composite, but ranges between 1370 °C to 1530 °C. 

Aluminum

Aluminum is a popular material for lightweight parts with low density. With a melt point of 660 °C, it is on the lower end of heat-resistant for metal 3D printing materials. 

_{Note: Heat resistance refers to melting point for all materials.}