What is ABS?

Acrylonitrile Butadiene Styrene (ABS) is a thermoplastic polymer widely used in 3D printing and many manufacturing processes. As its name suggests, ABS consists of three monomers: acrylonitrile, butadiene, and styrene. Each component contributes specific properties to the material:

Compatible With:

RM30 Series

RM40 Series

Acrylonitrile provides chemical resistance, heat stability, and toughness
Butadiene contributes elasticity, impact strength, and performance at low temperatures
Styrene offers rigidity, glossiness, and ease of processing

This combination creates an engineering-grade plastic with a unique balance of properties that made it one of the earliest materials adapted for FDM (Fused Deposition Modeling) 3D printing. The proportions of these components can be varied to produce different grades of ABS with slightly different characteristics for specific applications.

When heated to its melting point (typically around 210-250°C), ABS becomes fluid enough to be extruded through a 3D printer nozzle. As it cools, it solidifies into a durable, rigid object that can withstand significant mechanical stress, making it ideal for functional parts.

History of ABS

ABS has a rich history both in traditional manufacturing and 3D printing:

Early development: ABS was first developed in the 1940s by US Rubber Company (now Uniroyal) as a rubber-modified version of styrene-acrylonitrile copolymer. By the 1950s, it was being commercially produced.

Industrial adoption: Throughout the 1960s and 1970s, ABS became widely used in injection molding and extrusion manufacturing for consumer products, automotive components, and electronic housings.

Introduction to 3D printing: When Stratasys introduced the first commercial FDM 3D printer in the early 1990s, ABS was the primary filament material. This choice was logical given ABS's established position in traditional manufacturing and its suitable material properties for the FDM process.

RepRap and consumer 3D printing: When the RepRap project began developing open-source 3D printers in the mid-2000s, ABS was initially the dominant material alongside PLA. The first generation of commercial desktop 3D printers, like early MakerBot machines, were designed primarily with ABS printing in mind.

Evolution and competition: As the consumer 3D printing market evolved, many users found ABS challenging due to its printing requirements. This led to the rise of PLA as the most popular filament for beginners and the development of alternative materials like PETG that aimed to combine ABS's durability with easier printing characteristics.

Despite these challenges, ABS remains an important material in the 3D printing ecosystem, particularly for applications requiring durability, heat resistance, or post-processing capabilities.

Advantages of ABS for 3D Printing

ABS offers numerous benefits that continue to make it valuable for specific 3D printing applications:

Mechanical properties: ABS exhibits excellent impact resistance, toughness, and durability. It can withstand significant physical stress without breaking, making it ideal for functional parts and prototypes.

Temperature resistance: With a glass transition temperature of approximately 105°C, ABS maintains its structural integrity at much higher temperatures than many other common 3D printing materials like PLA (60°C) or even PETG (80°C). This makes ABS suitable for applications exposed to heat, such as automotive parts or household items near heat sources.

Chemical resistance: ABS resists water, alkalis, acids, and many household chemicals. This resistance makes it appropriate for parts that might be exposed to various substances during normal use.

Post-processing capabilities: One of the most distinctive advantages of ABS is its compatibility with acetone vapor smoothing. This process dissolves the surface layer of the print, eliminating layer lines and creating a smooth, glossy finish that's difficult to achieve with other materials.

Machinability: ABS can be easily drilled, sanded, tapped, and finished after printing. This makes it possible to integrate 3D printed ABS parts with other components or refine them for specific applications.

Painting and gluing: ABS takes paint well and can be effectively bonded using appropriate solvents or ABS slurry (ABS dissolved in acetone). This facilitates the creation of multi-part assemblies or customized finishes.

Recyclability: Failed prints can be ground up and extruded into new filament with the right equipment, though some material properties may degrade in the process.

Cost-effectiveness: ABS is generally more affordable than many specialty or engineering filaments, making it cost-effective for larger projects and functional prototypes.

Long-term stability: Properly printed ABS parts maintain their mechanical properties over extended periods, showing minimal degradation compared to some bioplastics.

Disadvantages of ABS

Despite its strengths, ABS presents several challenges that users should consider:

Warping and shrinkage: Perhaps the most notorious drawback of ABS is its tendency to shrink as it cools (approximately 0.7-0.9% linear shrinkage). This contraction can cause warping, curling, and layer separation, especially in parts with large flat surfaces or sharp corners.

Printing environment requirements: To minimize warping, ABS generally requires an enclosed print chamber with controlled temperature. This requirement limits which printers can effectively work with ABS.

Odor and emissions: During printing, ABS releases noticeable odors and potentially harmful ultrafine particles and volatile organic compounds (VOCs), including styrene. Proper ventilation is essential, making it less suitable for home or office environments without appropriate precautions.

Bed adhesion challenges: ABS requires a properly heated print bed and often additional adhesion solutions like ABS slurry, Kapton tape, or specialized adhesives to prevent prints from detaching during fabrication.

UV sensitivity: Prolonged exposure to ultraviolet light can cause ABS to yellow and degrade over time, limiting its suitability for outdoor applications unless properly coated or painted.

Moisture sensitivity: While less hygroscopic than materials like nylon, ABS filament can still absorb moisture from the air, which can lead to reduced print quality. Proper storage in airtight containers with desiccant is recommended.

Print surface quality: Without post-processing, ABS typically shows more visible layer lines than materials like PLA, and achieving fine details can be more challenging.

Environmental considerations: As a petroleum-based plastic, ABS is not biodegradable and requires proper disposal or recycling. It also has a higher environmental footprint in production compared to bio-based alternatives like PLA.

3D Printer Requirements for ABS

Successfully printing with ABS demands specific printer capabilities:

Enclosed printing chamber: An enclosed print area helps maintain a consistent ambient temperature around the print, significantly reducing warping and layer separation. Some printers come with built-in enclosures, while others might require DIY solutions.

Heated print bed: A bed capable of reaching and maintaining 100-110°C is essential for proper first layer adhesion and to minimize warping. The bed must heat evenly across its entire surface.

Hot end temperature capability: ABS typically prints at 230-250°C, so your printer must be able to reach and consistently maintain these temperatures. An all-metal hot end is highly recommended for regular ABS printing.

Build surface considerations:

Kapton (polyimide) tape was traditionally used for ABS
Glass beds with ABS slurry (ABS dissolved in acetone) or hairspray work well
PEI (Polyetherimide) sheets provide excellent adhesion for ABS
Textured spring steel sheets with appropriate coatings can work well and facilitate print removal

Printer frame and component quality: Since ABS prints at higher temperatures, the printer should have a frame that maintains stability and alignment even with the thermal expansion that occurs during extended prints.

Filtration or ventilation (recommended): While not strictly a printer requirement, proper ventilation or filtration is important when printing ABS to address odor and emissions concerns.

Higher-temperature capable components: PTFE tubing (if used) should be high-temperature rated, and any other parts near the hot end should be able to withstand the higher temperatures associated with ABS printing.

Firmware considerations: Some printers might need firmware adjustments to allow higher bed temperatures than the default settings permit.

Material Properties of ABS

Bed Temp	95-110°C
Density	1.04 g/cm3
Heated Bed	Required
Coefficient of Thermal Expansion	90 µm/m-°C
Ultimate Strength	40 MPa
Extruder Temp	220-250°C
Printability	Easy
Max Service Temp	98°C
Stiffness	Medium
Durability	High

How to Print with ABS - Tips and Tricks

To achieve the best results when printing with ABS, consider these practical tips:

Optimal print settings:

Nozzle temperature: 230-250°C (start at 240°C and adjust based on results)
Bed temperature: 100-110°C (105°C is a good starting point)
Print speed: 30-60 mm/s (generally slower than PLA)
Layer height: 0.1-0.3mm depending on the desired detail level
Cooling: Minimal or no cooling fan for most parts; small amounts (20-30%) might help with overhangs and bridges
First layer: Print slower (around 20 mm/s) and slightly hotter for better adhesion

Enclosure considerations:

Target ambient temperature: 45-60°C inside the enclosure
If using a DIY enclosure, ensure it's made of fire-resistant materials
Consider a thermometer to monitor internal temperature
Remember that higher ambient temperatures improve layer adhesion but can affect part accuracy if too extreme

Bed adhesion solutions:

ABS slurry (ABS dissolved in acetone) applied to a glass bed works extremely well
Hairspray (high-hold variety) can be an effective alternative
Commercial adhesives specifically designed for ABS
Ensure the bed is thoroughly cleaned before application
Consider a brim or raft for parts with small bed contact areas

Managing common print issues:

Warping:

Ensure proper enclosure temperature
Use a draft shield (a single-wall perimeter printed around your part)
Design with minimal sharp corners on the base
Orient parts to minimize large flat areas on the build plate
Consider splitting very large parts into smaller components

Layer separation (delamination):

Increase printing temperature
Ensure enclosure is maintaining adequate temperature
Check for drafts or temperature fluctuations
Consider redesigning to minimize sharp overhangs or sudden transitions

Stringing and oozing:

Optimize retraction settings (typically 4-6mm for Bowden setups, 1-3mm for direct drive)
Reduce temperature slightly if extrusion remains consistent
Print a temperature tower to find optimal temperature

Surface quality issues:

Consider acetone vapor smoothing for final finish
Use finer layer heights for better resolution
Ensure filament is dry before printing

Storage and filament care:

Store ABS in airtight containers with desiccant
If filament has absorbed moisture (indicated by popping or hissing during extrusion), dry at 70-80°C for 4-6 hours
Consider a filament dry box for extended prints in humid environments

Post-processing techniques:

Acetone vapor smoothing:

Place prints in a sealed container with acetone vapor (do not submerge directly in liquid acetone)
Monitor carefully to avoid over-smoothing which can distort details
Perform in a well-ventilated area away from ignition sources
Can be done using cold or warm methods (cold is safer but slower)

Mechanical finishing:

ABS sands well with progressive grits (start with 220 and work up to 600+)
Can be drilled, tapped, and cut with standard tools
Wet sanding reduces dust and improves finish

Bonding parts:

Use ABS slurry (ABS dissolved in acetone) as a strong adhesive
Commercial plastic welders work well with ABS
Some cyanoacrylate (super) glues compatible with ABS

Painting:

Light sanding or primer improves paint adhesion
ABS accepts most paints well, particularly acrylic and enamel
Consider using plastic-specific primers for best results

Environmental Considerations

The environmental impact of ABS is an important consideration:

Petroleum-based origin: Unlike PLA, which comes from renewable resources, ABS is derived from petroleum, making it less sustainable from a raw material standpoint.

Non-biodegradability: ABS does not biodegrade in natural environments and will persist for many decades if not properly recycled.

Recyclability: ABS falls under recycling code 9 (ABS) or sometimes 7 (Other) and is technically recyclable, though not all recycling facilities accept it. 3D printed ABS items may have additives or colorants that complicate commercial recycling.

Emissions during printing: The styrene and other volatile compounds released during printing raise air quality concerns, necessitating proper ventilation.

Energy usage: The higher temperatures required for printing ABS consume more energy than lower-temperature materials like PLA.

Lifecycle considerations: While ABS has higher environmental impacts in production and disposal, its durability means products last longer, potentially reducing the environmental impact of replacement cycles compared to less durable materials.

Reuse potential: Failed prints can potentially be reprocessed into new filament with appropriate equipment, though this may affect material properties.

ABS vs. Other Common Filaments

To better understand ABS's place in the 3D printing material landscape, it's helpful to compare it directly with other popular filaments:

ABS vs. PLA:

ABS is significantly more durable, flexible, and heat resistant
PLA is much easier to print, has less shrinkage, produces minimal odor, and is biodegradable
ABS requires an enclosure and higher temperatures, while PLA can print on almost any printer
ABS can be acetone smoothed; PLA requires mechanical finishing

ABS vs. PETG:

PETG has better layer adhesion and less warping than ABS
ABS has better heat resistance and is easier to post-process
PETG produces less odor and doesn't strictly require an enclosure
ABS is slightly lighter and typically less expensive

ABS vs. Nylon:

Nylon is more flexible and has superior wear resistance
ABS is less hygroscopic (absorbs less moisture) than nylon
Nylon requires even higher printing temperatures (250-270°C)
ABS is typically easier to obtain and less expensive

ABS vs. ASA (Acrylonitrile Styrene Acrylate):

ASA has superior UV resistance compared to ABS
Both have similar printing requirements and mechanical properties
ASA is often preferred for outdoor applications
ABS is typically less expensive and more widely available

What is ABS-CF?

ABS-CF (ABS Carbon Fiber) is a composite 3D printing filament made by combining ABS (Acrylonitrile Butadiene Styrene) with carbon fiber. The addition of carbon fiber enhances the material's mechanical properties, making it stronger, stiffer, and more durable than regular ABS.

Increased Strength and Stiffness: The carbon fiber in ABS-CF increases the filament's rigidity, making it much stiffer and more resistant to bending and deformation compared to standard ABS. It also provides improved tensile strength and impact resistance.

Lightweight: Carbon fiber is lightweight, so ABS-CF parts are still relatively light, even though they are stronger than regular ABS. This makes it ideal for applications where strength-to-weight ratio is important.

Improved Thermal Stability: ABS-CF retains the higher heat resistance of ABS, which can withstand temperatures of 90-100°C before softening. This makes it suitable for parts that need to endure heat without deforming.

Enhanced Surface Finish: The carbon fiber gives the filament a matte, textured finish, which can be aesthetically appealing. It can also reduce the appearance of layer lines and give printed parts a more professional look.

Abrasion Resistance: The inclusion of carbon fiber increases the abrasion resistance of ABS-CF, making it more durable for applications where the material will be subjected to wear and tear, such as moving parts or components that rub against surfaces.

Less Warping and Shrinkage: Like regular ABS, ABS-CF still has some tendency to warp, but it's generally less prone to warping than pure ABS due to the added stability from the carbon fiber. However, a heated bed (around 90-110°C) is still recommended.

Not right for you? Learn about other materials here.

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