Choosing Materials for Plastic and Rubber Component Production

When a company needs to produce a plastic or rubber component in series, choosing the material is one of the most important decisions.

Rigidity, flexibility, impact resistance, temperature and weather exposure can completely change which solution is most suitable. At the same time, especially for small and medium production runs, making a mold can require a significant initial investment and leave little freedom to modify the component later.

Additive manufacturing starts directly from a digital file and can produce functional components in series, allowing changes to geometry, material or quantity without a new mold.

Among the materials used by 3DRap Factory, PLA, PETG, ASA and TPU meet very different needs.

PLA: rigidity and precision

PLA is a rigid material offering good dimensional accuracy and the ability to achieve refined surfaces. It is particularly suitable for components used in controlled environments that are not exposed to high temperatures or prolonged weather exposure.

Its stability and ability to produce even complex shapes make it useful for rigid components, supports, technical elements and customized parts.

It is mainly used in industry, automation and design, and for functional components where precision, rigidity and cost control are important.

→ Case study: Series production and dynamic ROI calculation

PETG: versatility for functional components

PETG offers a good balance of rigidity, impact resistance and stability, making it particularly versatile for components intended for real-world use.

It is an interesting option for industry, automation, electronics, packaging and logistics, where customized functional components are often needed in varying quantities and designs must be adapted quickly.

One example comes from automation. 3DRap Factory developed a custom gripper for a collaborative robotic cell. In that project, batteries and electronic boards required antistatic properties and therefore a specific ESD polymer.

The case illustrates a fundamental principle: the material does not determine the project; actual operating conditions determine the right material.

→ Case study: Gripper for industrial automation

ASA: resistance for outdoor components

When a component operates outdoors, resistance to weathering becomes essential.

ASA offers good rigidity and is particularly valued for its UV and environmental resistance. It is therefore used in construction, window and door systems, automotive applications and technical installations, where components may face prolonged sunlight, moisture and temperature changes.

A particularly interesting application involves window and door systems, where 3DRap Factory has developed solutions for custom components and replacement parts.

Mold-free production makes it possible to manufacture limited quantities, handle different geometries and supply parts for discontinued systems, avoiding investment in new dedicated tooling.

→ Case study: Plastic and rubber components for window and door systems

TPU: when a component needs rubber-like behavior

When rigidity and hardness are not the desired properties, TPU offers a completely different production approach.

Its flexibility makes it possible to create components that deform, absorb impacts and vibrations, improve grip or protect the surfaces they contact. Adjusting material hardness and geometry can also substantially change the final component’s behavior.

These properties make TPU particularly interesting for automotive applications, automation, industry, packaging and logistics.

A practical example comes from the automotive sector, where 3DRap Factory developed flexible modular pads for trolleys used to transport components.

The outer surface was designed to be soft and protect the component by absorbing small impacts, while the internal structure provides greater stability. The modular solution also allows individual pads to be replaced and the same trolley to be reconfigured for different components without redesigning the entire system.

→ Case study: Modular pads for automotive trolleys

Material is only part of the result

Material selection is important, but it does not determine a component’s performance and final cost on its own.

Additive manufacturing involves many other parameters: infill percentage and geometry, wall count and thickness, component orientation, layer height, internal structure and production strategy.

That is why theexperience of the person preparing the print file can be decisive, sometimes even more than the material itself. A correctly designed component with appropriate print settings can achieve the required performance using a more common, affordable material, without necessarily requiring more expensive engineering polymers.

Optimizing material, geometry and production parameters together uses only the necessary amount of material, reduces manufacturing time and cost, and produces components suited to their function.

This balance of material, design and manufacturing expertise can generate considerable savings for companies, especially in small and medium production runs.

From requirement to component

You do not need to know in advance which material to use.

Starting from the application, operating conditions, required properties and production quantities, 3DRap Factory can assess the most suitable material, geometry and manufacturing parameters.

The goal is not to use the most expensive or technically advanced material, but to identify the solution actually needed to manufacture the component reliably and economically.