Even if you’re new to the world of 3D printing, you’ve probably heard of PLA filament, the most popular 3D printing material out there. Polylactic acid, commonly referred to as PLA, is a bioplastic and thermoplastic made from natural materials such as corn starch. It’s most known for its use in the 3D printing industry and sold in spools of a stranded material known as filament. But PLA plastic is also used in other manufacturing contexts due to its unique properties.
PLA is comparatively easy to work with, usually requiring minimal effort to produce quality parts, especially on an FDM 3D printer. As it’s created from natural or recycled materials, PLA is also embraced for its eco-friendliness, biodegradability, and many other characteristics.
In this article, we’ll go over everything about PLA plastic, especially with reference to its use in 3D printing. We’ll look at how this plastic is made, its pros and cons, uses, manufacturing methods, properties, sustainability issues, and more.
While this process may not happen right in front of you, it’s still good to know how a filament or material is made. Unlike many plastics, which are made by using refined crude oil, PLA is made from plant-derived substances such as corn starch and sugarcane.
First, the raw natural material, such as corn, undergoes wet milling, where the plant’s starch is isolated and separated. Following this extraction, the starch is mixed and heated with enzymes and other chemicals to release dextrose (D-glucose), a type of sugar. Then, the dextrose is fermented, producing lactic acid monomers, which polylactic acid is primarily made of (as you might be able to guess from the name).
The lactic acid can then be processed into PLA material in two ways: by condensing the lactic acid into a lactide and then using a polymerization process or by using a condensation process with the lactic acid directly. The former method is more common and involves binding the molecules together by adding different catalysts and heat.
Once the PLA is processed, the plastic is granulated and sold as a raw material. In the production of PLA filament, filament manufacturers first mix these PLA pellets with other substances. These additives typically enhance the final product’s properties, such as a different color, heat resistance, or strength.
The new mixture is then loaded into a special filament extruder that melts the grains and then cools them in a stringed form at a precise diameter (usually 1.75 or 2.85 mm). Finally, the stringed plastic is wrapped around a spool, packaged, and shipped around the world.
When PLA is used in contexts other than filament manufacturing, the process is very similar, except that the precise form varies depending on the intended end product.
PLA as a 3D printing material has some obvious advantages, but it’s important to recognize that this material isn’t perfect and has some drawbacks. Below, we’ve listed some of the benefits and disadvantages of this material.
PLA is the most popular 3D printing material, but it has plenty of uses besides 3D printing:
Now that you know the industries where PLA is most used, below are a few ways that PLA components are produced:
Although we’ve already mentioned a few material properties, such as brittleness, PLA plastic has many other properties worth discussing:
PLA is a material primarily meant for 3D printing, unlike other plastics such as ABS or polycarbonate which are predominantly used in other ways. Overall, PLA has a great printing performance, due to a few factors.
First, PLA doesn’t require a heated bed, enclosure, or direct drive extruder, so the equipment needed to print this material isn’t expensive, sometimes costing under $100. Materials such as ABS, PETG, and TPU all require at least one of these things to create quality prints.
Second, PLA is widely accessible, and the consumer 3D printing industry has grown enough that PLA filament is readily available online. It’s also pretty cheap, starting from around $20 per kilogram. Other filaments, such as PETG, costs a few extra dollars per kilogram, and there are fewer options.
Third, PLA is quite tolerant of varying print settings (within reason), so achieving a good print is pretty easy without a lengthy testing process to perfect slicer settings. Most default slicer profiles will leave you with a satisfactory model right off the bat, and just a little bit of adjustment can improve your prints even more. In contrast, ABS, PETG, and TPU are all sensitive to slicer settings, so your slicer profiles for these materials need to be delicately tuned to produce good prints.
Last, PLA can be printed more quickly than most other materials, and due to the desire for rapid prototyping, PLA is popular for quickly developing prototypes. No one wants to wait around for days until their first prototype is produced because, by then, they may have moved on to the next prototype!
Over the years, many unique types of PLA filament have emerged, giving the consumer many choices:
Now that you know the pros, cons, and types of PLA, you may want a spool or two of your own! While many companies make claims about the quality of the filament, a few are known for their reputation and consistent quality from spool to spool. Below is a list of some quality brands of PLA filament:
As we’ve mentioned, PLA plastic is sourced from plants such as corn instead of harmful materials like crude oil, which most other plastics are made from. This means PLA is a sustainable material for the most part, as plants are relatively renewable.
PLA is also technically biodegradable, but it takes a long time, even in an ideal environment, for PLA plastic parts to degrade. One study found that in a controlled composting environment, with heat and decomposing organisms to expedite the process, PLA plastic took three months to break down.
It would take even longer than three months for PLA to decompose in natural, uncontrolled conditions. So, it’s not like you can just toss all your old 3DBenchys in the composter or on the ground. Instead, it’s best to send PLA parts to a special facility meant for composting bioplastics.
The plants required to produce PLA are important as a food source, and some could argue that it’s not in the planet’s best interest to use these limited crops to make plastic over food. Perhaps in the future, PLA might be seen as an unsustainable material, if crop yields aren’t high enough to satisfy the need for both plastic and food.
Overall, while PLA is technically a sustainable material, it has some limitations. Still, PLA is a bioplastic and is more sustainable than other plastics, such as ABS, which rely totally on non-renewable resources and don’t decompose (or not nearly as quickly).
Lastly, it’s important to discuss the toxicity and food safety of PLA plastic, as this is a key consideration of using any material. PLA is a non-toxic material and can theoretically be used for producing food-safe items, unlike other 3D printing plastics such as ABS. However, many other factors contribute to the food safety of PLA, especially if it’s a 3D printed part.
Just because a material is non-toxic doesn’t mean it’s safe to come in contact with food. For example, FDM 3D printing creates parts layer-by-layer, and there are tiny gaps between these layers. These gaps can trap foreign particles, potentially contaminating the part and making it no longer food safe. Before this can even happen, though, PLA filament is fed through an extruder, tube, hot end, and nozzle, all locations where other, potentially unsafe, materials come into contact with the PLA.
With this in mind, it’s important to remember that while pure PLA plastic is non-toxic and food safe, other materials and particles can affect the safety of the finished part. We recommend consulting our guide to printing food-safe parts before attempting to print anything that will come into contact with food.
License: The text of "PLA Plastic/Material – The Ultimate Guide" by All3DP is licensed under a Creative Commons Attribution 4.0 International License.