A high-performance nylon 3D printer unlocks the potential to create exceptionally strong, flexible, and durable parts, but can your current machine handle this advanced material? If you’re looking to move beyond standard PLA and ABS, understanding the unique properties of nylon and the specific hardware requirements is crucial. This guide will walk you through everything you need to know to successfully print with nylon, from the different technologies available to essential tips for achieving high-quality results.
For those venturing into the world of engineering-grade materials, the prospect of printing with nylon offers a significant leap in functional prototyping and end-use part production. You’re in the right place to learn how to harness the power of this versatile polymer.
What is Nylon and Why is it a Top Choice in 3D Printing?
Nylon, a synthetic polymer also known as polyamide (PA), is a popular material in traditional manufacturing and has become a go-to choice for professional 3D printing. Its acclaim comes from a unique combination of properties that make it ideal for a wide range of applications.
The key benefits of using nylon in 3D printing include:
- Exceptional Strength and Durability: Nylon parts are tough and resistant to wear and abrasion, making them perfect for functional components.
- Flexibility: Unlike more brittle materials, nylon offers a degree of flexibility, which is advantageous for parts that need to bend without breaking.
- Chemical Resistance: It holds up well against many chemicals, oils, and solvents.
- High-Temperature Resistance: Certain grades of nylon can withstand significant heat, expanding their use in demanding environments.
These properties make nylon a favored material for producing gears, living hinges, jigs, fixtures, and custom-fit parts in the automotive, aerospace, and medical industries.
Technologies for Printing with Nylon
Not all 3D printers are created equal when it comes to handling nylon. The two primary technologies that excel at printing this robust material are Fused Deposition Modeling (FDM) and Selective Laser Sintering (SLS).
Fused Deposition Modeling (FDM/FFF)
FDM, or Fused Filament Fabrication (FFF), is a widely accessible 3D printing method that uses a filament extruded through a heated nozzle. To successfully print with nylon filament, your FDM printer needs specific features:
- All-Metal Hotend: Nylon requires high extrusion temperatures, typically between 240°C and 290°C, which can degrade or melt the PTFE liners found in standard hotends.
- Heated Print Bed: A bed temperature of around 70°C to 120°C is necessary to prevent the first layers from cooling too quickly and warping.
- Print Bed Adhesion: A specialized print surface like a Garolite or perforated build plate, often with the addition of a PVA-based glue stick, is recommended for optimal adhesion.
- Enclosure: An enclosed build chamber helps maintain a stable ambient temperature, which is critical for preventing warping and layer splitting.
Selective Laser Sintering (SLS)
SLS is an industrial 3D printing process that uses a high-powered laser to fuse powdered material, layer by layer. Nylon is the most common material used in SLS, and for good reason. This technology offers several advantages for producing nylon parts:
- Design Freedom: SLS nylon 3D printer does not require support structures, as the unfused powder supports the part during printing. This allows for the creation of complex geometries and intricate internal features.
- Superior Mechanical Properties: SLS-printed nylon parts exhibit more isotropic properties, meaning they have consistent strength in all directions.
- High Throughput: SLS machines can often nest multiple parts within the build volume, making it an efficient process for producing small to medium batches of functional parts.
Critical Requirements for Successful Nylon Printing
Successfully printing with nylon requires careful attention to a few key areas, regardless of the technology used.
Moisture: The Enemy of Nylon
Nylon is highly hygroscopic, meaning it readily absorbs moisture from the surrounding air. If the filament or powder contains too much moisture, it can lead to a host of printing problems, including:
- Popping and Sizzling at the Nozzle: The absorbed water turns to steam and can cause inconsistent extrusion.
- Poor Surface Finish: The print may appear rough or have a fuzzy texture.
- Reduced Part Strength: The mechanical properties of the final part will be compromised.
To combat moisture, it is essential to:
- Store nylon filament in a dry box or a sealed container with desiccant.
- Dry the filament in a dedicated filament dryer or an oven at a low temperature before printing.
- For SLS, maintain a controlled environment for powder storage and handling.
Achieving a Strong First Layer
Good bed adhesion is the foundation of a successful FDM print. Without it, you’re likely to experience warping, where the corners of the print lift off the build plate.
- Use the right build surface: Garolite, phenolic, and specially formulated print surfaces work well with nylon.
- Apply an adhesive: A thin layer of PVA glue stick or a specialized bed adhesive can significantly improve first-layer stick.
- Optimize your first layer settings: A slightly slower and hotter first layer can promote better adhesion.
Weighing the Pros and Cons of Nylon 3D Printing
| Pros | Cons |
| High strength and durability | Prone to warping |
| Excellent flexibility | Highly sensitive to moisture |
| Good abrasion and chemical resistance | Requires a high-temperature hotend |
| Can be used for functional, end-use parts | Can be more expensive than other filaments |
| Available in various formulations (e.g., carbon fiber reinforced) | Requires a controlled printing environment |
A Step-by-Step Guide to Printing Nylon with an FDM Printer
- Prepare Your Filament: Dry your nylon filament for at least 4-6 hours at the manufacturer’s recommended temperature.
- Prepare Your Printer:
- Ensure you have an all-metal hotend.
- Clean your build plate and apply an adhesive if necessary.
- Pre-heat your nozzle and bed to the recommended temperatures. If you have an enclosure, allow the internal temperature to stabilize.
- Dial in Your Slicer Settings:
- Extrusion Temperature: 240°C – 290°C
- Bed Temperature: 70°C – 120°C
- Print Speed: 30-60 mm/s (slower speeds are generally better)
- Cooling Fan: Turn the part cooling fan off or use a very low setting (10-20%).
- Retraction: Fine-tune your retraction settings to minimize stringing.
- Troubleshoot Common Issues:
- Warping: Use a brim or raft, and ensure your enclosure maintains a consistent temperature.
- Stringing: Increase retraction distance and speed, or try a slightly lower print temperature.
- Poor Layer Adhesion: Increase the print temperature or reduce the cooling fan speed.
Choosing the Best Nylon Material for Your Needs
The world of nylon for 3D printing extends beyond a single type. Here’s a quick look at some popular options:
- Nylon 6: Offers excellent strength and is a good general-purpose choice.
- Nylon 12: Known for its superior chemical resistance and lower moisture absorption, making it easier to print.
- Carbon Fiber Reinforced Nylon: The addition of carbon fibers significantly increases the stiffness and strength of the nylon, making it suitable for high-performance applications.
- Glass-Filled Nylon: Provides enhanced thermal resistance and dimensional stability.
When selecting a nylon filament or powder, consider the specific requirements of your application, such as the need for flexibility, heat resistance, or extreme strength.
Real-World Inspiration: What Can You Create with a Nylon 3D Printer?
The applications for 3D printed nylon are vast and continue to grow. Here’s a real-world example:
A small engineering firm was tasked with developing a custom drone for agricultural surveying. The drone’s landing gear needed to be lightweight yet incredibly durable to withstand rough landings in a variety of terrains. After several failed attempts with ABS and PETG, which were too brittle, the team turned to a carbon fiber nylon filament. By using a nylon 3D printer with an enclosure and a hardened steel nozzle, they were able to produce landing gear that was not only strong and impact-resistant but also flexible enough to absorb the shock of landing. This allowed them to rapidly iterate on their design and create a functional prototype that met all of their client’s requirements.
Other applications include:
- Automotive: Custom brackets, clips, and interior components.
- Prototyping: Functional prototypes that can be subjected to real-world testing.
- Consumer Products: Durable housings for electronics, custom sporting goods, and more.
- Industrial: Jigs, fixtures, and low-volume production parts.
Ready to Print with Nylon?
Printing with nylon can be a challenging yet rewarding endeavor. By understanding the material’s properties and ensuring your nylon 3D printer is properly equipped and calibrated, you can unlock a new level of performance and durability in your 3D printed parts.
