The Materials Powering Innovation at RapidMade

In modern manufacturing, selecting the right material is just as important as the design itself. The choice affects everything from durability and flexibility to cost-effectiveness and performance. Whether it’s a lightweight prototype, a high-strength aerospace component, or a corrosion-resistant industrial part, material selection can make or break a product’s success.

Advancements in 3D printing materials, thermoforming, and machining have expanded the range of materials available, giving manufacturers more options than ever. At the forefront of this revolution is RapidMade, a company providing a wide variety of materials tailored to different industries, applications, and performance requirements.

3D Printing Materials: A New Era of Manufacturing

3D printing has transformed the manufacturing industry by allowing for intricate designs, rapid prototyping, and cost-effective production without expensive tooling. RapidMade specializes in four primary 3D printing technologies: Multi Jet Fusion (MJF), Stereolithography (SLA), Fused Deposition Modeling (FDM), and Metal 3D Printing. Each offers unique advantages depending on the application.

Multi Jet Fusion (MJF) for Durable, High-Detail Parts

Multi Jet Fusion is an advanced powder-based printing method known for its high-speed production and excellent mechanical properties. It is widely used in industries requiring durable and detailed components. One of the most popular materials for MJF is Nylon PA-12, a lightweight yet strong plastic with excellent chemical resistance, making it ideal for industrial and consumer applications. For projects that require flexibility, Thermoplastic Polyurethane (TPU) provides rubber-like properties with superior wear resistance, making it a preferred choice for gaskets, seals, and medical devices.

Stereolithography (SLA) for Precision and Smooth Finishes

Stereolithography is a high-resolution 3D printing process that uses a laser to cure liquid resin, creating smooth, detailed parts. This method is particularly valuable for prototypes, cosmetic models, and intricate components. Standard acrylic-based resins offer rigid, smooth surfaces with fine detail, while X Pro 9400 B FR, a flame-retardant and high-temperature-resistant resin, is ideal for aerospace and automotive applications. For products that require flexibility, High Rebound Elastomer provides a soft-touch feel and excellent energy return, making it useful in grips and seals.

Fused Deposition Modeling (FDM) for Tough, Industrial-Grade Plastics

Fused Deposition Modeling is a cost-effective manufacturing method that uses thermoplastics to produce strong, durable parts. It is widely used in industries such as automotive, aerospace, and industrial tooling. ABS (Acrylonitrile Butadiene Styrene) is a popular FDM material due to its impact resistance and affordability, making it perfect for enclosures and fixtures. Polycarbonate (PC) provides high-impact resistance and optical clarity, while Ultem 9085, an aerospace-grade thermoplastic, offers extreme heat resistance and flame retardancy.

Metal 3D Printing for High-Strength and Corrosion Resistance

For industries requiring the highest levels of durability, metal 3D printing delivers unparalleled performance. 316L stainless steel is widely used in marine, medical, and food-grade applications due to its superior corrosion resistance. 17-4 PH stainless steel, on the other hand, offers high hardness and strength, making it a go-to material for aerospace and tooling applications.

Thermoforming Materials: Scalable, Cost-Effective Production

For projects requiring large, durable parts at scale, thermoforming provides an efficient and affordable alternative to injection molding. This process involves heating and molding plastic sheets into custom shapes, making it a popular choice for automotive, aerospace, and packaging industries.

Standard Thermoplastics for Versatile Applications

Thermoforming offers a range of cost-effective plastic options that balance durability and affordability. High-Impact Polystyrene (HIPS) is a widely used material in packaging and disposable trays, thanks to its low cost and ease of forming. ABS, with its excellent impact resistance, is commonly used in automotive panels and protective enclosures. PETG (Polyethylene Terephthalate Glycol-Modified) is valued for its clarity and FDA approval, making it a go-to material for medical trays and food packaging.

High-Performance Thermoplastics for Specialized Needs

For industries requiring superior strength, chemical resistance, and heat tolerance, high-performance thermoplastics provide solutions for demanding environments. Polycarbonate (PC) is frequently used in machine guards and protective barriers due to its high impact strength and optical clarity. Kydex®, a fire-retardant ABS/PVC blend, is a preferred material in aircraft interiors and medical equipment due to its flame resistance and durability. The latest innovation, Aerolite Thermoformable Carbon Fiber, combines the strength of carbon fiber with the moldability of thermoforming, making it ideal for aerospace and high-performance automotive parts.

Machining Materials: Unmatched Precision and Strength

Unlike additive manufacturing, which builds parts layer by layer, machining removes material from a solid block, achieving high precision and exceptional surface finishes. This makes it ideal for functional parts requiring extreme durability and tight tolerances.

Machinable Metals for Strength and Durability

For applications where high strength, corrosion resistance, and wear resistance are essential, machined metals offer unmatched reliability. Aluminum (6061, 7075) is lightweight yet strong, making it widely used in aerospace and structural components. Stainless steel (303, 304, 316, 17-4, 440C) is valued for its corrosion resistance, with applications in medical, marine, and industrial industries. Carbon steels and alloy steels, including 4140 and 4340, are commonly used in structural and mechanical applications due to their high impact resistance and ability to withstand extreme conditions.

Machinable Plastics for Lightweight, High-Performance Components

For industries where weight, chemical resistance, and electrical insulation are crucial, machined plastics provide the necessary flexibility and performance. Delrin (Acetal/POM) is known for its low friction and high wear resistance, making it ideal for gears and bearings. Nylon offers self-lubricating properties, making it suitable for bushings and structural components. Polycarbonate (PC) provides impact resistance and transparency, commonly used in machine guards and optical applications. For extreme conditions, PEEK (Polyetheretherketone) is one of the most resilient plastics available, resistant to heat, radiation, and chemicals, making it a prime choice in aerospace and medical industries.

The Right Material for Every Application

Selecting the right material is crucial in ensuring performance, longevity, and cost-effectiveness. Whether you need high-strength metals, flexible plastics, or heat-resistant composites, RapidMade offers a comprehensive selection of advanced materials tailored to diverse industry needs.

From rapid prototyping to large-scale production, RapidMade provides expert guidance to help businesses choose the best material for their applications. Whether you’re an engineer designing a breakthrough product or a manufacturer looking for cost-effective solutions, RapidMade has the materials and expertise to bring your ideas to life.

Explore the full range of manufacturing solutions at rapidmade.com and take your designs from concept to reality with cutting-edge materials and world-class expertise.