What is HIPS?
High Impact Polystyrene (HIPS) represents a versatile and widely-used thermoplastic material that has become particularly significant in the world of 3D printing. Designed as a modified version of standard polystyrene, HIPS offers enhanced mechanical properties that make it an attractive option for various additive manufacturing applications.
HIPS is fundamentally a polystyrene polymer that has been modified with polybutadiene rubber particles. This unique molecular structure provides:
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Improved impact resistance
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Enhanced mechanical flexibility
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Better overall structural integrity compared to standard polystyrene
History of HIPS
The story of High Impact Polystyrene begins in the early 20th century with the initial synthesis of polystyrene. In 1839, German apothecary Eduard Simon first discovered polystyrene by accident while studying the natural resin of the Turkish sweetgum tree. However, it wasn't until the 1930s that commercial production became viable.
The breakthrough came during World War II when materials scientists sought to develop more durable plastics for military and industrial applications. By adding polybutadiene rubber particles to standard polystyrene, researchers created a material that could absorb impact much more effectively than its predecessor.
In the 1950s, manufacturers began seriously exploring impact-modified polystyrene. The key innovation was the incorporation of rubber particles within the polystyrene matrix. These microscopic rubber particles act as stress absorbers, creating a material that could withstand significantly more mechanical stress without catastrophic failure.
Throughout the 1980s and 1990s, HIPS became a staple in various manufacturing processes:
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Packaging industries embraced its lightweight nature
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Consumer electronics utilized its electrical insulation properties
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Toy manufacturers appreciated its durability and low cost
The rise of desktop 3D printing in the late 2000s presented a perfect opportunity for HIPS. Its unique properties made it an ideal support material, particularly for ABS printing. The material's ability to dissolve in limonene created a revolutionary approach to complex multi-material printing techniques.
Advantages of HIPS for 3D Printing
Exceptional Impact Resistance: Significantly more durable than standard polystyrene
Superior Printability: Smooth and consistent extrusion characteristics
Excellent Dimensional Stability: Minimal warping during printing
Smooth Surface Finish: Produces high-quality, clean print surfaces
Easy Dissolution: Easily removable with limonene, making it ideal for support structures
Low Printing Temperature: Requires relatively low extrusion temperatures
Compatibility: Works well with ABS and can be used as a support material
Cost-Effective: More affordable compared to many engineering-grade polymers​
Lightweight: Low density material
Good Electrical Insulation: Useful for electronic prototyping
Moderate Chemical Resistance: Suitable for various environmental conditions
Ease of Post-Processing: Can be easily sanded, painted, and machined
Disadvantages of HIPS
Low Temperature Resistance: Softens at relatively low temperatures
Limited Mechanical Strength: Compared to engineering-grade polymers
Moisture Sensitivity: Prone to absorbing environmental moisture
Poor UV Resistance: Degrades quickly when exposed to sunlight
Non-Biodegradable: Significant environmental persistence
Petroleum-Based: Derived from non-renewable resources
Recycling Challenges: Limited recyclability compared to some other plastics​
Brittle Nature: Can crack under significant mechanical stress
Limited Chemical Resistance: Vulnerable to certain solvents and chemicals
Short-Term Durability: Not suitable for long-term, high-stress applications
Potential Warping: Can deform under inconsistent cooling conditions
Material Properties of HIPS
Bed Temp | 100-115°C |
Density | 1.04 g/cm3 |
Heated Bed | Required |
Coefficient of Thermal Expansion | 80 µm/m-°C |
Ultimate Strength | 32 MPa |
Extruder Temp | 230-245°C |
Printability | Medium to Difficult |
Max Service Temp | 100°C |
Stiffness | Very High |
Durability | Medium to High |
Designing for HIPS
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Dissolvable Supports: HIPS is often used as a support material in dual-extrusion 3D printers alongside ABS. It can be dissolved in limonene, which makes it an excellent choice for complex geometries that require support material.
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Soluble Support Structures: If using HIPS as support, ensure your print settings for the primary filament (like ABS) are optimized to handle the separation and removal of HIPS easily once it's dissolved.
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Optimal Support Density: When printing with HIPS as support, use a low-density support structure. This will make it easier to dissolve in limonene and also reduce the overall print time and material usage.
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Support Placement: Keep the support structures to a minimum. For parts with large overhangs, experiment with different support patterns (like grid or tree supports) to ensure easy removal.
How to print with HIPS - Tips and Tricks
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Use a Heated Bed: Set your heated bed to around 90°C to 110°C. HIPS prints best on a heated bed, and this will help with adhesion and reduce warping.
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Use a Build Surface: To improve adhesion, you can use a PEI sheet or blue painter’s tape on the print bed. Some users also recommend a light layer of glue stick to ensure strong adhesion to the bed.
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Kapton Tape: If you're using a heated bed, Kapton tape can also help with adhesion, as HIPS sticks well to it.
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Extruder Temperature: HIPS typically prints at a temperature of around 230°C to 250°C. Ensure the hotend can reach and maintain these temperatures for consistent extrusion.
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Print Cooling: HIPS doesn’t require a lot of cooling. Use a low to moderate fan speed (around 20-30%) to help with layer bonding. Too much cooling can cause warping or poor layer adhesion.
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Print Speed: For better print quality, keep the print speed around 40-60 mm/s. Slower speeds can improve the overall finish and layer bonding.
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Layer Height: A standard layer height of 0.1 to 0.2 mm works well for most prints. You can go slightly higher for quick drafts or prototypes, but finer layers will give you better detail.
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Enclosure: Since HIPS is sensitive to temperature fluctuations, printing in an enclosed build chamber will help prevent warping and ensure consistent thermal conditions.
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Avoid Rapid Cooling: Reduce the cooling fan speed or turn it off for the first few layers to allow the print to cool slowly, preventing warping.
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Ambient Temperature: HIPS, like ABS, is prone to warping due to temperature changes, so try to maintain a stable ambient temperature in your printing area. Avoid drafts or sudden temperature fluctuations to minimize warping or cracking during the print.
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Moisture Sensitivity: HIPS is not as moisture-sensitive as some other filaments, but it can still absorb moisture over time. Store your filament in a dry box or sealed bag with desiccants to avoid any printing issues like bubbling or poor extrusion.
Post-Processing Considerations with HIPS
Sanding and Painting: HIPS can be easily sanded and smoothed to create a high-quality surface finish. Use fine-grit sandpaper to smooth out any rough surfaces. It also takes paint very well, so it can be used for aesthetic or prototype parts that need a smooth, finished appearance.
Limonene Dissolution: If you used HIPS as a support material, dissolve the supports by soaking the printed part in limonene (a citrus-based solvent). This process is very effective at removing the support material without damaging the model.
Applications of HIPS
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Prototyping
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Architectural model development
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Initial design iteration for mechanical components
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Concept visualization in product design
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Engineering Domains
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Temporary support structures
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Low-stress mechanical component prototyping
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Educational and training model creation
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Specialized Sectors
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Medical device prototype development
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Educational scientific models
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Experimental design visualizations
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Low-cost replacement part fabrication
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Consumer and Hobby Applications:
- Tabletop gaming miniatures
- Custom household item prototyping
- Art and sculpture modeling
- Educational project development
Not right for you? Learn about other materials here.
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