The Challenge Facing Functional 3D Printed Parts
Over the past decade, photopolymer 3D printing technologies such as SLA, DLP, and LCD have evolved from rapid prototyping tools into viable manufacturing solutions for engineering applications.
As industries increasingly rely on additive manufacturing for functional prototypes, assembly verification, tooling, and low-volume production, the expectations placed on photopolymer materials continue to rise.
However, one challenge remains common across many ABS-like resins available on the market today:
High strength does not always mean high durability.
Many materials can achieve impressive flexural or tensile strength values, yet fail prematurely when subjected to impact, assembly stress, repeated handling, or real-world functional testing.
This creates a gap between laboratory performance and actual engineering requirements.
Why Traditional ABS-Like Resins Often Fail
Most standard ABS-like photopolymer resins are designed to prioritize rigidity and dimensional accuracy.
While these characteristics are important, excessive crosslink density can result in:
- Increased brittleness
- Poor impact resistance
- Crack propagation during assembly
- Reduced service life under dynamic loading
As a result, engineers frequently encounter situations where a printed part looks excellent but cannot withstand real operating conditions.
Common failures include:
- Cracking around screw holes
- Breaking during snap-fit assembly
- Fracture during drop testing
- Failure under repetitive mechanical stress
For industries such as automotive, consumer electronics, and industrial equipment manufacturing, these limitations can significantly reduce the value of additive manufacturing.
The New Performance Standard: Strength + Toughness
The next generation of engineering photopolymers is no longer defined by strength alone.
Instead, manufacturers are seeking materials that combine:
High Structural Strength
Required for:
- Load-bearing components
- Functional prototypes
- Engineering fixtures
- Assembly verification parts
High Impact Resistance
Required for:
- Snap-fit structures
- Product housings
- Automotive interior components
- Consumer electronic enclosures
The ideal engineering resin must achieve both properties simultaneously.
This balance is often difficult because increasing strength typically reduces toughness, while increasing toughness may reduce rigidity.
Achieving both requires advanced resin chemistry and optimized polymer network design.
What Engineering Customers Are Really Looking For
Based on discussions with industrial users worldwide, several material requirements consistently appear across different industries:
Automotive Industry
Automotive manufacturers require materials that can survive assembly operations and withstand vibration, handling, and functional testing.
Consumer Electronics
Product development teams need durable housings capable of repeated installation and disassembly without cracking.
Industrial Manufacturing
Factories increasingly use 3D printed fixtures, jigs, and tooling components that must withstand long-term operational loads.
Product Development Centers
Engineering teams seek materials that better simulate the performance of injection-molded ABS parts during validation and testing.
In all these applications, toughness is becoming just as important as strength.
A New Direction for ABS-Like Engineering Resins
Modern resin development is shifting toward engineering-grade materials capable of delivering:
- High flexural strength
- High impact resistance
- Excellent printability
- Low shrinkage
- Stable dimensional accuracy
These characteristics help bridge the gap between traditional prototyping materials and true functional engineering plastics.
As additive manufacturing continues moving toward end-use applications, material performance will become one of the most important factors influencing adoption.
Looking Ahead
The future of industrial photopolymer materials lies in balanced performance.
Rather than focusing on a single property, manufacturers and engineers are increasingly evaluating materials based on their ability to deliver:
- Strength
- Toughness
- Reliability
- Processability
- Long-term durability
For functional prototypes and engineering applications, the question is no longer:
"How strong is the material?"
The real question is:
"Can the part survive real-world use?"
As material technology continues to evolve, advanced ABS-like engineering resins are expected to play a critical role in expanding the capabilities of industrial 3D printing.
About EVERAY
EVERAY specializes in the development and manufacturing of UV resin oligomers and advanced photopolymer materials for industrial applications.
Our focus is helping customers develop next-generation 3D printing materials that combine performance, reliability, and scalability for global markets.
For technical discussions or sample requests, please contact our team.