01
The part warps off the bed
Large flat ABS or PP panels cool unevenly and curl at the corners. If the first layer lifts more than 0.5 mm, the whole build is scrap and the assembly will not sit flat.
Plastic Additive Manufacturing
3D Printing Plastics
Pick a plastic, a process, and a layer height that survive real use. We print prototypes and small runs, then machine the same geometry in POM, PEEK, or ABS when the plastic part has to hold tolerance.
PLA / ABS / PETGPA12 and PA6 nylonSLA and DLP resin±0.1 mm typicalNo minimum orderDFM feedback in 12 hours
2011Operating since
7,600 m²Manufacturing space
no MOQOne part to 10,000+
12 hQuote and DFM analysis
Where plastic prints go wrong
Four failures that arrive with the box
Most plastic print problems are decided before the file is uploaded. Here is what we see on incoming jobs.
02
Threads strip on first assembly
Printed threads below M4 shear when a screw is torqued. The fix is a metal insert or a machined boss, not a finer layer height.
03
Creep under a constant load
A PLA bracket that holds 20 kg for a week will bend and stay bent. Load-bearing parts need a different polymer, or a machined part.
04
Dimensional drift across a batch
FDM parts shrink as they cool. Without a shrink factor dialed in, holes come out 0.2–0.4 mm undersized and pins will not fit the mating plate.
How we run plastic printing
Match the plastic and the process to the job
Seven processes under one roof, plus CNC when the print cannot hold the tolerance.
Material selection
Choosing among 3D printing plastics
PLA is the easiest to print and the cheapest per part, but it creeps under load and softens near 60 °C. Use it for form checks and display models. PETG adds toughness and a wider working range, and it prints almost as easily.
ABS and ASA bring low-temperature impact resistance, dimensional stability, and good chemical resistance, so they suit enclosures and functional housings. Nylon is strong, wear-resistant, and low in density, which makes it the usual choice for living hinges, clips, and gears.
- 1PLAPrototypes, jigs, non-structural covers. Not for heat or sustained load.
- 2ABS and ASAEnclosures, brackets, automotive interior trim samples.
- 3PETGParts needing toughness, transparency, or mild chemical contact.
Process selection
FDM, SLA, SLS, and DLP: which one fits
FDM lays a thermoplastic filament down in layers from 0.1 mm to 0.3 mm. It is the workhorse for brackets, housings, and fixtures, and it takes inserts and tapped holes well if you design enough wall.
SLA and DLP cure liquid resin with light, so they hold detail that FDM cannot. Resin parts come out smooth and dimensionally tight, which is why dental models, surgical guides, and small connectors go that route. SLS sinters nylon powder with no support marks, so it handles nested geometry and small production batches.
- 1FDMLayer height 0.1–0.3 mm. Best cost per part for larger shapes.
- 2SLA and DLPFine detail, smooth surface, tight dimensions on small parts.
- 3SLSNylon PA12, no support scars, good for 10–500 part runs.
Material comparison
Plastic selection at a glance
Mechanical values vary by supplier and print orientation. Use this to narrow the list, then confirm with a test part.
| Material | Heat resistance | Best for |
|---|---|---|
| PLA | Low, softens near 60 °C | Form checks, jigs, display models |
| PETG | Moderate, about 70 °C | Tough covers, transparent parts |
| ABS / ASA | Moderate, about 90 °C | Enclosures, housings, interior trim |
| Nylon PA12 | Moderate to high | Clips, gears, living hinges |
| Resin (SLA) | Low to moderate | Dental, surgical guides, fine detail |
| POM (machined) | Moderate, about 90 °C | Tight-tolerance moving parts |
| PEEK (machined) | High, above 250 °C | High-temperature and chemical service |
Services
Plastic part services we run in-house
Print, machine, finish, and inspect from one shop. That removes the handoff where tolerance usually gets lost.
01
Custom 3D Printing
FDM, SLA, DLP, and SLS in PLA, ABS, PETG, nylon, and resin. One part or a small production batch.
02
Rapid Prototyping
Printed form and fit models, then a machined version of the same geometry for functional testing.
03
CNC Milling and Turning
POM, PEEK, ABS, PC, PMMA, and PA machined to ±0.005 mm when a printed part cannot hold size.
04
Vacuum Casting
Silicone molds from a printed master for 10–50 polyurethane parts with a consistent surface.
05
Part Surface Finishing
Bead blasting, tumbling, painting, and laser marking with a minimum character height of 1.5 mm.
06
Sheet Metal Fabrication
Metal frames and enclosures that the printed plastic covers, brackets, and guides mount onto.
Scope
What a plastic printing order includes
Every job follows the same route, whether it is one part or a thousand.
| Item | What we do | Output |
|---|---|---|
| File review | Check wall thickness, draft, and hole size | DFM notes within 12 hours |
| Material | PLA, ABS, ASA, PETG, PA12, resin | Matched to load and temperature |
| Build | FDM 0.1–0.3 mm, SLA, DLP, or SLS | Parts plus support removal |
| Machining | Holes, faces, and threads cut after printing | Critical features to ±0.005 mm |
| Inspection | Raw material check, in-process, final | Reports on request |
| Shipping | Protected packs, batch labels | Parts ship in 3–5 days |
Why GreatLight
Printing backed by a machine shop
The reason most plastic printing projects stall is that no one can fix the geometry. We can.
15Y
15 years in production
Operating since 2011 across three wholly-owned plants and 7,600 m² of floor space, with 150 technicians on staff.
127
127 CNC machines on site
When a printed plastic part needs a flat face or a true bore, it moves to a mill instead of waiting on a new supplier.
±0.005 mm
Machined tolerance
Printed parts hold roughly ±0.1 mm. Critical features can be cut after printing to ±0.005 mm, or ±0.0002 in.
24 h
Production start
Quotation and free DFM analysis within 12 hours. Production can begin within 24 hours of approval.
<2%
Historical late-delivery rate
Parts ship in 3–5 days, and the historical probability of a late shipment sits below 2%.
100%
Inspection before shipment
Raw material check, in-process monitoring, and final inspection on every order. Reports on request.
ISO 9001:2015Quality management
IATF 16949:2016Automotive quality
ISO 13485:2016Medical devices
ISO 27001:2022Information security
Industry results
What these industries require, and what we deliver
Consumer product housings
Snap fits and cosmetic covers need a clean surface and repeatable wall thickness. ABS and ASA hold the shape; printed masters feed vacuum casting for 10–50 units.
- Wall 1.5–2.5 mm
- Ra 0.8–1.6 μm after finishing
- 10–50 unit runs
Enclosure and case parts
Cases must close flush and survive a drop. We print the shell, then machine the mating faces and hinge bores so the lid lines up.
- Mating faces to ±0.005 mm
- Drop-test samples
- Batch labels per unit
Mechanism and pivot parts
Moving joints need clearance, wear resistance, and no creep. Nylon or machined POM replaces PLA, and pivot holes are reamed after printing.
- Nylon or POM
- Reamed bores
- Creep-resistant material
Nested and thin-wall geometry
Internal channels and lattice shapes rule out milling. SLS nylon prints them without support marks, and we inspect wall thickness before the run.
- SLS PA12
- No support scars
- 10–500 part batches
FAQs
Questions engineers ask before ordering
Which plastic should I pick for a functional part?
Start with the load and the temperature. PETG covers most general functional parts with better toughness than PLA.
For clips, gears, and living hinges, use nylon. For enclosures that see heat or chemicals, use ABS or ASA. PLA stays on the shelf as a form-check material.
What tolerance can plastic 3D printing hold?
Expect roughly ±0.1 mm on a well-oriented FDM part, and better on SLA or DLP for small features. Hole diameters drift undersized because the material shrinks as it cools.
If a bore, face, or thread must be true, we print oversize and cut it after printing. That gets critical features to ±0.005 mm.
When should I switch from printing to CNC machining?
Switch when the part carries a sustained load, sees more than 90 °C, or needs a tolerance tighter than ±0.1 mm.
Printed plastics also creep. If a bracket holds a constant load for weeks, a machined POM or PEEK part is the safer route. We quote both so the comparison is direct.
Do you print threads, or should I use inserts?
Printed threads below M4 tend to strip. Use a heat-set insert or a machined boss for anything that gets assembled more than once.
We can tap the printed part where the wall is thick enough, or cut the thread after printing on a mill.
What wall thickness and layer height should I design to?
Aim for 1.5–2.5 mm walls on FDM parts, with at least three perimeters. Thinner walls flex and print with gaps.
Layer height runs 0.1–0.3 mm. Use 0.1 mm for visible or mating surfaces and 0.2–0.3 mm for large non-critical shapes.
Can you match a specific color or surface finish?
We print in the standard colors the material comes in, then finish from there. Options include bead blasting, tumbling, painting, and polishing.
Laser marking is available with a minimum character height of 1.5 mm.
How do you handle my design files?
Uploads are secure and confidential, and we can sign an NDA on request. Files are used only for quoting and producing your parts.
We hold ISO 27001:2022 for information security, so document handling follows a documented process.
What is the smallest order you take?
There is no minimum order quantity. We run one prototype or a 10,000+ part batch.
For a batch above a few hundred units, we compare printing against vacuum casting and machining and quote the cheaper route.
Send a plastic part and get a real answer
Upload your file and we return a quotation with free DFM analysis within 12 hours. If printing is the wrong process for that part, we will say so and quote the alternative.
12-hour quote100% inspectionNo minimum orderNDA on request
