Exploring the Applications and Constraints of PLA and ABS Materials in Structural Additive Manufacturing: A Review

The rapid advancement of fused deposition modeling (FDM) has positioned polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) as leading materials for structural 3D printing (3DP). This review paper critically examines the applications and inherent limitations of PLA and ABS in structural contexts by additive manufacturing (AM). AM, particularly FDM, has emerged as a sustainable fabrication technology enabling the conversion of various thermoplastics into functional structural components. This study reviews and synthesizes findings from recent research on the mechanical and thermal performance of recycled and virgin polymer materials — specifically ABS, PLA processed through 3DP. PLA is a biodegradable polymer made from renewable sources. Though PLA is biodegradable, its performance changes after printing due to altered crystallinity and layer adhesion. It is easy to print, has high-dimensional accuracy, and can create detailed features with minimal warping. However, its brittleness and poor heat resistance restrict its use in demanding structural applications. Meanwhile, ABS has shown promise for sustainable filament development, offering enhanced thermal stability and tensile strength while reducing environmental impact. ABS also exhibits superior toughness, impact resistance, and higher thermal stability, enabling its deployment in more robust and functional end-use parts. Nevertheless, ABS presents challenges such as increased warping, the need for controlled printing environments. This paper also explores emerging trends in multi-material printing and the potential for combining PLA and ABS to harness their complementary properties. This paper aims to guide material selection and process optimization for structural 3DP, while highlighting avenues for future research and innovation.