3D Printing with Polystyrene (High Impact Polystyrene (HIPS)):

The Evolution of Polystyrene to 3D Printing with High Impact Polystyrene (HIPS)

If you’re looking to dive into the world of 3D printing with polystyrene, specifically High Impact Polystyrene (HIPS), you’ve come to the right place. With 30 years under my belt in the mechanical manufacturing sector, I've seen the evolution of materials and technologies, and HIPS is one that has grabbed a lot of attention recently.

So, grab a coffee, sit back, and let’s get into the nitty-gritty of 3D printing with HIPS.

What is High Impact Polystyrene (HIPS)?

First things first, what exactly is HIPS?
High-impact polystyrene is a type of polystyrene that’s been modified with rubber to enhance its durability and impact resistance. Think of it as the tougher cousin of your regular polystyrene. You’ve probably encountered HIPS in everyday products like disposable cups, food containers, and even model kits.

Why Use HIPS for 3D Printing?

1. Support Material

One of the standout features of HIPS is its use as a support material. If you’re printing complex objects with overhangs and intricate designs, HIPS can be a lifesaver. It dissolves in limonene, making it easy to remove from your finished print without leaving a trace.

2. Durability

HIPS is tough. It’s resistant to impact, which means your prints can withstand a bit of rough handling. This makes it ideal for prototypes, functional parts, and models that need a bit of robustness.

3. Ease of Printing

HIPS prints at a relatively low temperature, around 230°C, and adheres well to a heated bed at about 90-110°C. It’s less prone to warping compared to some other filaments, which means fewer failed prints and headaches.

Getting Started with HIPS

1. Printer Settings

To get the best results with HIPS, you’ll need to dial in your printer settings. Here’s a quick rundown:

• Nozzle Temperature: 230°C to 240°C
• Bed Temperature: 90°C to 110°C
• Print Speed: 30-60 mm/s
• Cooling: Minimal or no cooling

Real-World Applications of HIPS in 3D Printing

1. Prototyping

High-impact polystyrene (HIPS) is a standout material when it comes to prototyping, thanks to its exceptional properties. Prototyping often requires a material that can be both versatile and durable, and HIPS fits the bill perfectly. Here’s why:

Durability and Functionality

The inherent durability of HIPS means that the prototypes you create aren’t just showpieces—they’re functional.
This material can withstand a reasonable amount of stress and impact, allowing you to test the actual performance of your prototype under real-world conditions.

This is particularly beneficial in mechanical and structural prototyping, where the robustness of the material can give you a better understanding of the final product’s performance.

Ease of Use and Quick Iterations

HIPS is known for its ease of use in 3D printing. It adheres well to the print bed and has minimal warping issues, which results in fewer print failures and smoother printing processes.

This reliability means you can quickly iterate your designs, making adjustments and printing new versions without the frustration of dealing with common print issues.

Fast iterations are crucial in the prototyping phase, as they allow for rapid development and refinement of designs based on real-time feedback and testing.

Cost-Effective

Prototyping can be an expensive process, especially when multiple iterations are involved. HIPS is relatively cost-effective compared to some other high-performance materials. This affordability makes it an excellent choice for extensive prototyping projects where budget considerations are important.

2. Model Making

Model making is another area where HIPS shines, offering a unique combination of detail and strength that is highly valued by hobbyists and professionals alike.

Architectural Models

For architects and designers, creating detailed and accurate scale models is an essential part of the design process. HIPS allows for high-resolution prints, capturing fine details with precision.

Its strength ensures that even delicate structures within the model are sturdy and durable, making it easier to transport and present these models without fear of damage.

Figurines and Custom Parts

Hobbyists and artists often turn to HIPS for creating figurines and custom parts. The material’s ability to be sanded and painted means that post-processing is straightforward, allowing for high-quality finishes.

Whether you’re crafting a detailed action figure, a custom game piece, or a decorative item, HIPS provides the necessary detail and durability.

Educational Models

In educational settings, detailed models are used to demonstrate concepts and ideas. HIPS is perfect for creating educational aids such as anatomical models, geographical replicas, or mechanical parts.

Its ease of printing and finishing means that educators can produce high-quality, durable models that enhance learning experiences.

3. Functional Parts

HIPS is not just for show—it’s capable of creating functional parts that need to withstand regular use and stress, making it a versatile material in practical applications.

Impact Resistance

One of the key properties of HIPS is its impact resistance. This makes it suitable for producing parts that will undergo wear and tear.

For example, brackets and mounts that need to hold weight or sustain minor impacts can be reliably printed with HIPS, ensuring they perform well in their intended roles.

Mechanical Parts

In the realm of mechanical applications, HIPS can be used to create gears, pulleys, and other moving components. Its durability ensures that these parts can operate smoothly and reliably.

The ease of printing with HIPS allows for precise manufacturing of parts that need to fit and function together seamlessly.

Custom and Replacement Parts

For custom projects or repairs, HIPS is a go-to material. It can be used to produce custom-designed parts tailored to specific needs or to replace broken components.

Its versatility means it can be used in a wide range of applications, from household repairs to automotive parts, providing a reliable solution for unique problems.

Electrical Housings and Enclosures

Due to its insulating properties, HIPS is also suitable for creating housings and enclosures for electrical components.

It can protect sensitive electronics from external impacts and provide a stable, durable casing that ensures longevity and safety.