Additive Manufacturing Materials

1. What do AM materials need to do?

They must feed reliably into the machine, fuse or cure consistently layer after layer, and deliver final part properties after post-processing. Unlike conventional stock, AM materials are judged as much on processability as on bulk properties.

2. Which process families and materials are used?

3. Which terms appear in specifications?

Build orientation (XY, Z), layer thickness, particle size distribution (D10, D50, D90), apparent and tap density, Hall flow, moisture content, oxygen and nitrogen content, refresh ratio, virgin and reused powder, filament diameter and ovality, cure depth, post-cure, heat treatment, hot isostatic pressing (HIP), witness coupons. Terminology is standardised in ISO/ASTM 52900 (S1).

4. Which material properties should be specified?

For filaments: diameter and ovality tolerance, moisture, colour and certified composition. For polymer powders: particle size distribution, bulk density, flow, melting behaviour and the recommended refresh ratio. For resins: viscosity, cure parameters and shelf life. For metal powders: chemical composition, particle size distribution, morphology, flow, density and interstitial elements. Alloy and process specifications such as ASTM F2924 define requirements for particular materials (S2).

5. How is material cost per part estimated?

Material consumed per part includes the part itself, supports or sacrificial structures, and losses from purging, failed builds or powder that cannot be reused. Dividing the useful material by a yield factor gives a planning figure. The example shows arithmetic only.

6. Why do printed properties depend on orientation?

Layers bond to each other differently from how material bonds within a layer, so strength, elongation and fatigue often differ between XY and Z directions. Specify the orientation of test specimens and of critical part features, and include witness coupons in production builds where properties must be demonstrated.

7. Why must material and machine parameters be qualified together?

Every AM process turns material into a part through a parameter set: laser power and scan strategy, layer thickness, chamber and bed temperatures, extrusion temperature and speed, exposure time and so on. A material supplier's data are measured with a particular machine and parameter set; another machine model, firmware version or parameter set can change density, strength and surface quality even with the same material lot. Production programmes therefore qualify a material–machine–parameter combination and treat changes to any of them as controlled changes. When requesting materials, ask which machines and parameter sets the supplier's data refer to, whether validated parameter files are available, and what the supplier recommends when parameters are adapted to your machine.

8. Why do powder handling and reuse matter?

Powder that has been through a build is exposed to heat and atmosphere; polymer powders age and metal powders can pick up oxygen or change particle size. Most processes mix reused and virgin powder at a defined ratio. Sieving, storage in controlled conditions, lot tracking and periodic testing keep the feedstock within specification.

9. How are AM materials produced?

Filaments are extruded and wound with diameter control; polymer powders are produced by grinding, precipitation or other processes; resins are formulated and packaged in light-protective containers; metal powders are produced by gas, plasma or water atomisation, then sieved and classified. Each route affects morphology and processability.

10. How does post-processing affect final properties?

Photopolymers need washing and post-curing; polymer powder parts are de-powdered and sometimes smoothed or dyed; metal parts are stress-relieved, heat-treated, sometimes HIPed, removed from build plates and machined. Post-processing parameters are part of the material qualification.

11. Which problems are common?

12. Which safety and storage points apply?

Fine metal powders can be combustible and require handling procedures, grounding and inert storage where specified; polymer powders and resins have their own safety data sheet requirements, and uncured resins can be skin sensitisers. Store materials sealed and within the stated conditions; dry hygroscopic filaments and powders before use.

13. Where are AM materials used industrially?

Prototypes, jigs and fixtures, tooling inserts, low-volume and customised end-use parts, aerospace and medical components, spare parts and lightweight structures. The application decides how much qualification and documentation is required.

14. Which requirements depend on the application?

Aerospace, medical and energy parts may require material and process specifications, traceability and documented qualification; consumer and industrial parts may need flammability or food-contact documentation; tooling needs heat and wear resistance. State these at the start.

15. How should a buyer select a material?

1. Describe the part, its loads and environment, and the AM process and machine.
2. State property targets, orientation and post-processing.
3. Ask material manufacturers for specifications, lot data and machine-specific parameter guidance.
4. Build qualification specimens and parts; test properties and dimensions.
5. Lock material, machine, parameters and post-processing in a build specification.

16. How should build qualification be run?

Build test specimens in the orientations that matter, alongside representative parts, from at least two material lots where possible. Test mechanical properties, density, dimensions and surface, after the defined post-processing. Record machine, parameters, powder ratio and lots. Repeat after any change of lot or parameter that the specification defines as significant.

17. Which documents should be requested?

Material specification and data sheet; certificate per lot with chemistry, particle data or diameter data; safety data sheet; storage and handling guidance; machine-specific parameter recommendations; regulatory statements where relevant; and change-notification commitment.

18. How does AM compare with conventional manufacturing for a part?

19. What determines total cost?

Material price per kilogram, material use per part, machine time, powder refresh losses, post-processing labour, inspection and qualification, and scrap. Higher material cost can be justified by geometry, consolidation of parts or lead-time savings.

20. What should an AM material RFQ include?

• Process, machine model and parameter source.
• Material family or specification and form (filament, pellet, powder, resin).
• Property targets, orientation and post-processing.
• Documentation and traceability requirements.
• Quantity per lot, annual volume, packaging and delivery location.

Prepare and submit these through the RFQ brief.

21. Which manufacturer qualification questions should be asked?

Materials and forms produced; lot testing and certificates; machine-specific data; production route (for powders, atomisation method); quality systems; regional supply; and change control. PAXOMER does not confirm any manufacturer's capabilities on this page.

22. Which related pages should be read next?

• Guide: 3D printing and additive manufacturing materials
• Related page: Engineering plastic compounds
• Related page: PCR recycled resins

Engineering and purchasing FAQs

Each answer is general technical information, not a specification or a quotation.

Can I use any brand of powder in my machine?

Why are printed parts weaker in the Z direction?

How much powder can be reused?

Do filaments need drying?

Which documents should come with each lot?

Can PAXOMER help source additive manufacturing materials?

Technical References

References below were opened on the access date shown. A source supports only the statement it is cited for. Standards are cited by number and title from public catalogue entries; their full text was not read unless stated.

1. S1. ISO/ASTM 52900:2015 Additive manufacturing — General principles — Terminology. ISO, 2015. www.iso.org/standard/69669.html (opens in a new tab) standard catalogue · accessed 2026-10-28
   Catalogue entry opened 2026-10-28 to confirm number and title; full text not read.
2. S2. ASTM F2924: Standard Specification for Additive Manufacturing Titanium-6 Aluminum-4 Vanadium with Powder Bed Fusion. ASTM International. store.astm.org/standards/f2924 (opens in a new tab) standard catalogue · accessed 2026-10-28
   Catalogue entry opened 2026-10-28 to confirm number and title; full text not read.
3. S3. ASTM D638: Standard Test Method for Tensile Properties of Plastics. ASTM International. store.astm.org/standards/d638 (opens in a new tab) standard catalogue · accessed 2026-10-28
   Catalogue entry opened 2026-10-28 to confirm number and title; full text not read.
4. S4. 3D printing and additive manufacturing materials (PAXOMER guide). PAXOMER Inc., 2026-10-28. /products/3d-printing-additive-manufacturing-materials/ technical literature · accessed 2026-10-28
   PAXOMER’s own guide; not an external source and not independently reviewed.