Strongest 3D Printing Filaments
Need materials that deliver real performance? Here's how to choose filaments with the strength your applications demand.
Material strength can make or break your 3D printed parts—literally. Whether you're prototyping a drone component that needs to survive crash testing or creating production-ready brackets for automotive applications, the right filament choice determines if your parts perform beautifully or fail spectacularly.
Strength in 3D printing is not one-size-fits-all. A filament might excel in tensile strength but fail under impact, or perform well at high heat but lack rigidity. Understanding these trade-offs helps you select materials that perform where it matters most.
Understanding 3D Printing Materials
The world of 3D printing materials splits into three main categories: filaments (for FDM printing), powders (for SLS and MJF), and resins (for SLA).
Filaments are thermoplastic wires fed through heated nozzles to build parts layer by layer, making them the go-to choice for desktop and industrial FDM printing, which is available through Protolabs Network
Different Types of Material Strength
When we talk about "strong" filaments, we're really discussing a few different properties.
- Tensile strength: Measures resistance to pulling forces, which are critical for structural components, brackets, and load-bearing parts. Carbon fibre composites and ULTEM materials (like ULTEM 1010 and 9085) excel here, with values ranging from 70-103 MPa.
- Impact strength: Determines impact resistance and how well materials absorb sudden shocks without fracturing. Measured in Joules per metre (J/m), engineers often vet this quality for parts that face drops, vibrations, or collisions. Markforged Onyx leads at up to 330 J/m, while standard materials like PLA typically achieve only 25-30 J/m.
- Thermal strength: Covers performance at elevated temperatures. ULTEM 1010's ability to maintain properties at 217°C makes it a top choice for automotive under-bonnet components, while ABS fails around 80°C.
- Chemical resistance: Important when your parts will face harsh chemicals, fuels, or corrosive environments. Nylon-based filaments handle these challenges much better than PLA or ABS.
Benefits of Our 3D Printing Services
Protolabs brings together expertise in high-strength filament printing with access to both desktop and industrial FDM capabilities through our network. We specialise in advanced materials, from carbon fibre composites requiring hardened nozzles to high-temperature polymers needing precise thermal control.
Through Protolabs Network, you get access to:
- Industrial-grade filaments like ULTEM and carbon fibre composites often used for aerospace applications.
- Specialised hardware including hardened nozzles and heated chambers essential for printing demanding materials.
- Process expertise in managing warping, layer adhesion, and other challenges common with high-strength filaments.
- Quality assurance with dimensional inspection and standardised reporting across our network.
Strongest 3D Printing Filament Options
Here's how the strongest FDM filaments measure up when they go head-to-head and thread-to-thread.
|
Filament Type |
Tensile Strength (MPa) |
Heat Resistance (°C) |
Impact Strength (J/m) |
Cost |
Key Benefits |
|
89 |
186 |
88-120 |
€€€€ |
Excellent strength-to-weight, flame retardant |
|
|
103 |
217 |
80-95 |
€€€€ |
Superior heat resistance, chemical resistance |
|
|
70-90 |
150-180 |
124 |
€€€ |
High stiffness, lightweight, dimensional stability |
|
|
36-71 |
145 |
330 |
€€ |
Exceptional impact resistance, excellent surface finish |
|
|
60-70 |
120-150 |
140-155 |
€€ |
Superior impact resistance, chemical resistance |
Note: Values represent FDM-printed performance and vary based on print settings, layer orientation, and specific formulations. Lead times are from 3 business days. Additional specialty materials are available by request through Protolabs Network.
Considerations for Selecting Filaments
Choosing high-strength filaments is a juggling act of considerations that extends well beyond raw strength numbers. Understanding material capabilities helps you select the right option for your application while making sure your project stays to spec and within budget.
- Where will it live? Operating temperatures, chemical exposure, and UV conditions your part will face.
- What will it need to withstand? Whether you need tensile strength, impact resistance, or heat performance.
- What's your budget? ULTEM materials cost 3-5x more than standard nylon, which may be worth it for some applications, overkill for others.
- How complex is your design? Intricate geometries and thin features limit your material choices.
- How quickly do you need it? Industrial materials add about 1 business day vs. prototyping options.
- How many do you need? Higher quantities can justify premium material costs that don't make sense for one-offs.
Quick Decision Framework
|
If You Need... |
Consider... |
Design Considerations |
Typical Cost |
|
Maximum strength + heat |
ULTEM 1010 |
Design for thermal expansion, consider wall thickness |
€€€€ |
|
Balanced performance |
Carbon fibre nylon |
Account for anisotropic properties, avoid thin features |
€€€ |
|
Impact resistance |
Markforged Onyx |
Excellent for snap-fits, shock absorption |
€€ |
|
Cost-effective strength |
Standard nylon |
Good for most applications, watch moisture sensitivity |
€€ |
|
Rapid prototyping |
PETG |
Works for concept validation, limited temperature range |
€ |
Prototypes vs. Final Products
Material choice strategy differs significantly between prototyping and production applications, with each requiring different material characteristics and performance priorities. Desktop and industrial FDM systems offer distinct advantages for each use case.
Filaments for Prototyping
For prototypes, you're typically validating form, fit, and function rather than long-term durability. This opens up cost-effective options like PETG or ABS that provide adequate strength for testing while remaining economical for design iteration.
Prototype Considerations
- Cost efficiency is key since lower-priced materials allow rapid design iteration.
- Focus on form, fit, and function rather than long-term durability.
- Fast feedback loops matter more than absolute strength.
Available Materials
Industrial Filaments for Production
Industrial materials are engineered for consistent performance, traceability, and long-term reliability in production environments. These branded materials (Stratasys, Markforged) represent carefully controlled formulations with documented properties, certified supply chains, and lot traceability essential for production parts.
Production Part Considerations
- Proven long-term reliability under real conditions.
- Consistent mechanical properties batch-to-batch.
- Environmental resistance matching application demands.
- Cost per part becomes critical at volume.
Available Materials
- Nylon: Markforged Onyx
- PEI: ULTEM 9085, ULTEM 1010
- ASA: Stratasys ASA
- ABS: ABS M30
When transitioning from prototype to production, you can also consider powder-based technologies like SLS and MJF, or even metal 3D printing, to access an even wider range of endurance properties for end-use parts.
Applications by Industry
Different industries push materials to their limits in distinct ways. Here's how the strongest filaments perform across key sectors:
Aerospace: For parts that are skyward bound, the balance between strength and weight is paramount. ULTEM filaments are widely used in aircraft interiors, ducting, and non-critical structural components where their flame-retardant properties and strength-to-weight ratio are essential.
Medical: When lives depend on your prototypes working perfectly, ULTEM's biocompatibility and chemical resistance gives it an edge. From surgical instrument prototypes to diagnostic equipment housings, these high-performance filaments handle sterilisation cycles and demanding environments that would destroy lesser materials.
Automotive: Under the bonnet is no place for weak materials. Carbon fibre nylon thrives in these harsh conditions, from engine housings that face constant heat cycling to custom brackets that must survive years of vibration. The material's thermal stability means parts that keep working when others would warp or crack.
Consumer Electronics: When your product needs to look good and work reliably, Markforged Onyx delivers both performance and appearance. Its excellent surface finish and impact resistance make it perfect for housing prototypes that need to survive the inevitable drops and knocks of real-world use.
Designing For Strong Filaments
High-strength filaments behave differently from standard plastics. Knowing their quirks helps you design parts that deliver the performance you expect.
- Moisture sensitivity: Nylon-based materials absorb humidity easily. Thick sections can trap moisture and weaken over time. Use hollow features or drainage paths to reduce risk.
- Print orientation and anisotropy: Parts printed with layers perpendicular to stress can be 20–40% weaker than those aligned with the load. Carbon fibre filaments are especially strong along the layer direction but weak between layers. Always design load paths to follow the print grain.
- Thermal expansion: ULTEM expands and contracts more than standard plastics. Account for this movement by adjusting tolerances and joint designs.
- Layer adhesion: Smooth transitions and rounded corners reduce stress concentrations at layer interfaces and improve overall strength.
Quality Assurance in 3D Printing
High quality is our top priority, especially with strong filaments where performance is critical. Every order goes through structured assurance processes designed to give engineers confidence:
- DFM analysis: Each quote includes automated checks to flag potential issues like thin walls, inaccessible surfaces, or text resolution problems before printing begins.
- In-process quality checks: Skilled additive manufacturing technicians perform quality checks on every unique geometry as builds progress.
- Visual inspection: Parts undergo a visual inspection to ensure consistency with your 3D model.
- Dimensional sampling: Key dimensions are sampled to verify that basic dimensions meet quoted tolerances.
- Certified reporting options: For AS9100-certified processes (SLS, MJF, and DMLS), we offer AQL Level II sampling with several reporting choices including AS9102 First Article Inspection (FAI), Build Reports, Dimensional Inspection Reports (DIR), and Reference Reports. This gives engineers flexibility to select the level of documentation that matches their project requirements.
Quality control is also rigorously implemented at Protolabs Network, which is AS 9100 D / ISO 9001: 2015 certified, with additional certifications available through our manufacturing partners.
FAQ
What is the strongest 3D printing filament?
expand_less expand_more"Strongest" depends on your application. ULTEM 1010 at 103 MPa tensile strength, though Markforged Onyx leads impact resistance at 330 J/m.
Is strength the same as stiffness?
expand_less expand_moreNo. Stiffness is resisting deformation; strength is withstanding force.
Can strong filaments be used for functional prototypes?
expand_less expand_moreYes, and they often reduce the gap between prototyping and production.
How do strong filaments compare in cost?
expand_less expand_moreThey cost more upfront but save by extending part life and reducing failures.
Are carbon fibre filaments always stronger?
expand_less expand_moreNot always. They boost stiffness but can reduce impact resistance. Onyx outperforms carbon fibre nylon for shock absorption.
When should I use powder materials instead?
expand_less expand_moreWhen filaments can't meet your strength requirements. SLS and MJF often provide superior performance.
Do I need special CAD considerations for strong filaments?
expand_less expand_moreYes, several factors matter more with high-strength materials. Design thicker walls (minimum 1.5mm), avoid sharp internal corners that create stress concentrations, and consider how your part will be oriented during printing. Our DFM analysis flags potential issues automatically during quoting.
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