Archive — Originally published in 2020, this guide introduces ABS and ASA for large-format 3D printing. Material performance depends on the grade and the printing process.
Large-format 3D printing is used for prototypes, tooling and components across different industries. The available processes use different feedstocks; a material suitable for one application is not automatically appropriate for another.
This guide focuses on ABS and ASA thermoplastics, including their use in material-extrusion processes. It distinguishes their properties from those of the photopolymer resins used by other printing technologies.
What is large format 3D printing?
Large-format 3D printers offer a larger build envelope for producing substantial parts in one piece or reducing the number of assembled sections. There is no single build-volume threshold that defines the category. Examples cited in the original 2020 article included the Builder Extreme 2000 PRO, Modix BIG-120X and BigRep STUDIO G2; model specifications and availability should be checked with the manufacturers.
Technologies used in large-format 3D printing
- Material extrusion (FFF/FDM): a heated nozzle deposits thermoplastic material layer by layer. ABS and ASA can be supplied as filament or, for compatible equipment, pellets.
- Laser stereolithography (SLA): a laser selectively cures liquid photopolymer resin. Printed parts may require washing, support removal and post-curing according to the resin supplier’s instructions. Where isopropanol is specified, it is used to wash parts, not to clean a room.
- Digital light processing (DLP): a projector using micromirrors exposes a layer of resin. This differs from an LCD-masked resin printer. Neither process turns a photopolymer into ABS or ASA.
Large systems also exist for polymer powder-bed fusion, including selective laser sintering, and for metal processes such as laser powder-bed fusion. Their feedstocks and processing requirements differ from those of ABS and ASA extrusion.
What is ABS?
ABS stands for acrylonitrile butadiene styrene. It is an amorphous thermoplastic that softens over a temperature range rather than having the sharp melting point of a crystalline material. It can be heated and shaped under controlled conditions, but excessive heat or repeated processing can degrade it.
The original article named Stratasys, eSUN, Formfutura and Ultimaker among ABS filament suppliers. Photopolymer products marketed as “ABS-like” are a different material family: they aim to reproduce selected properties and are not ABS. Their performance and ageing behaviour must be checked separately.
How is ABS made?
ABS combines a styrene-acrylonitrile phase with a rubber phase based on polybutadiene. Industrial production includes emulsion and mass polymerisation routes. Formulation and processing influence the balance of stiffness, toughness and other properties.
ABS can also be mechanically recycled where collection, sorting and processing are suitable. Recycled ABS is a particular feedstock choice, not the standard origin of every ABS product, and its properties still require verification.
ABS properties and practical limitations
- Impact resistance and stiffness: ABS is used for tough engineering parts, but the balance varies by grade and print orientation.
- Heat and chemical resistance: assess the expected temperature, chemicals and exposure time against the supplier’s data. Increasing rubber content does not automatically improve every property.
- Finishing: sanding, bonding and other finishing methods may be possible; the work required depends on the surface and application.
- Appearance and insulation: suitable grades can provide a good surface finish and electrical insulation. These characteristics do not by themselves establish a safety rating for a printed component.
- Cost and recycling: ABS can be economical in some workflows, but it is not necessarily the cheapest material, and recyclability depends on the available recovery route.
The printed part’s performance also depends on layer adhesion, build orientation, voids, geometry and process settings. Properties measured on moulded test pieces should not be applied automatically to an FFF part.
ABS can warp as it cools, particularly on large parts. An appropriate enclosure and controlled print conditions may help, while ventilation must address printing emissions. Outdoor UV exposure is a limitation compared with ASA. Follow the material and printer suppliers’ instructions, including storage and drying guidance; see the Prusa ABS guide for an example of these considerations.
Where is ABS used?
ABS is used in moulded products such as automotive parts, consumer goods, pipe fittings and construction toys. These examples describe the material family; they do not establish that a printed replacement meets the requirements of the original product.
- Automotive trim and housings.
- Consumer-product enclosures.
- Selected pipe fittings and other moulded components.
- Construction toys, including LEGO bricks.
What is ASA?
ASA stands for acrylonitrile styrene acrylate. It was developed as a material with useful mechanical properties and improved weathering resistance compared with conventional ABS. This makes suitable ASA grades relevant to automotive and other outdoor applications.
How is ASA made?
ASA uses an acrylic rubber phase with styrene-acrylonitrile. Its formulation differs from the polybutadiene-based rubber system in ABS. Weathering and mechanical performance depend on the complete formulation, not on acrylonitrile alone.
ASA properties and practical limitations
- Weathering resistance: ASA is commonly chosen for better resistance to UV exposure than standard ABS.
- Mechanical and thermal properties: suitable grades offer a useful balance for functional parts; values must be checked for the intended service conditions.
- Surface appearance: finish, colour retention and gloss depend on grade and processing.
ASA and ABS share some uses, but their properties are not identical. ASA also requires controlled print conditions and ventilation; it is not exempt from warping or emissions. The Prusa ASA guide describes these printing considerations.
Where is ASA used?
- Outdoor housings and prototypes.
- Selected automotive components.
- Electrical and electronic enclosures where the grade meets the required specifications.
- Garden and lawn equipment components.
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