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PP (Polypropylene SLS/MJF)

polymer

semi-crystalline thermoplastic polyolefin

PolypropyleneHP 3D HR PPHP MJF PPSLS PPPolypropylene powderPP SLSTPO (related olefin family)
Density
0.91 g/cm³
YS (SLS as-built (XY))
22–29 MPa
UTS (SLS as-built (XY))
28–36 MPa
Elongation (SLS as-built (XY))
12.0–30.0 %
Elastic modulus
1–2 GPa

Mechanical & thermal properties — 2 conditions

PropertySLS as-built (XY)MJF as-built (HP 3D HR PP, XY)
Elastic modulus1–2 GPa1–2 GPa
Yield strength (0.2%)22–29 MPa25–32 MPa
Ultimate tensile strength28–36 MPa30–40 MPa
Elongation at break12.0–30.0 %18.0–35.0 %
Density0.88–0.94 g/cm³0.90–0.95 g/cm³

Values shown as min–max where a spread is reported, otherwise as typical ± unit. Ranges reflect inter-source variation, not single-sample scatter. All values are for AM-processed specimens unless noted.

Engineering considerations

  • Living hinge design: PP's key advantage over PA12 is living hinge fatigue life. For living hinges, design per DIN 16740 / standard PP living hinge guidelines: hinge thickness 0.3–0.5 mm, generous radii at hinge transitions, parallel orientation to build plate (XY). Test hinge at ≥10,000 cycles before production qualification. MJF PP produces more consistent hinge properties than SLS PP.
  • Shrinkage management in SLS: PP linear shrinkage ~3–4% is higher than PA12 (~2.5%). Apply a PP-specific scale factor in the build file. Shrinkage is also more sensitive to bed temperature uniformity — use conservative packing density (25–35%) and avoid placing PP parts at the bed periphery where thermal gradients are higher.
  • Autoclave validation: for sterile medical device applications, validate the full autoclave cycle (121°C, 15 min, 15 psi steam) per ISO 17665. PP parts printed by MJF (HP 3D HR PP) have been validated to survive ≥50 autoclave cycles with <2% dimensional change in HP application studies. SLS PP: validate independently as sintering conditions affect crystallinity and heat resistance.
  • Chemical compatibility: verify compatibility against specific chemical environments. PP resists: HCl, H₂SO₄ (dilute), NaOH, alcohols, most aliphatic hydrocarbons. PP is attacked by: fuming HNO₃, concentrated H₂SO₄, chlorinated solvents (DCM, chloroform), aromatic hydrocarbons (toluene, xylene). For chemical plant use, verify against ASTM/NACE PP chemical resistance data at service temperature.
  • Post-processing bonding: standard adhesives do not bond well to PP without surface activation. For bonded assemblies, specify plasma treatment (air or O₂ plasma, 30–60 s) or corona discharge before adhesive application. PP-compatible adhesives: 3M DP8005, Loctite 406+770 primer, or structural acrylic adhesives. Mechanical fasteners (through-bolts, threaded inserts) are more reliable than adhesive bonding for structural joints.
  • Moisture: PP absorbs <0.01% moisture — virtually no drying required before printing (unlike PA12 which must be dried). Dimensional stability in humid environments is excellent. For applications in contact with water or humid air, PP significantly outperforms PA12 (which absorbs ~0.25% water in equilibrium).
  • Powder refresh ratio: HP recommends 80% recycled powder for MJF PP (more generous than PA12 at 70%). SLS PP: limit to 40–50% recycled for structural parts — PP powder yellowing and MFR increase with thermal cycling. Monitor powder MFR — if MFR increases >30% from virgin value, discard batch.

Advantages

  • Lowest density of any common SLS/MJF polymer (0.91–0.93 g/cm³) — maximum weight reduction for volume-constrained designs
  • Exceptional chemical resistance: broad resistance to acids, bases, alcohols, and most organic solvents — outperforms PA12 in chemical-contact applications
  • Autoclavable at 121°C (standard steam sterilisation) — enables medical device applications that PA12 cannot serve (PA12 degrades above ~80°C service temperature)
  • Living hinge performance: PP's combination of semi-crystalline structure and flexibility gives outstanding fatigue life in repeated flex — orders of magnitude better than PA12
  • Food-safe and USP Class VI grades available — enables packaging and food-contact applications
  • No moisture absorption: PP is virtually non-hygroscopic (<0.01% water uptake) — dimensional stability in humid environments and no drying required before printing
  • Good impact resistance at low temperatures: PP retains toughness to approximately –10°C (with adequate wall thickness)
  • Support-free powder bed process — same DfAM freedom as PA12/SLS: complex internal channels, interlocks, living hinges printed without support removal

Limitations

  • Challenging SLS processing: high crystallisation shrinkage (~3–4% linear) creates warpage risk — requires precise thermal management and conservative packing density
  • Limited SLS machine ecosystem: not all SLS machines are optimised for PP; EOS and Farsoon machines require specific parameter sets. HP MJF 5200/580 has better-qualified PP parameters
  • AM parts 20–25% weaker than injection-moulded PP: SLS/MJF porosity reduces strength vs IM. Critical structural applications should use safety factors accordingly
  • Lower stiffness than PA12: E ~1.4–1.5 GPa vs ~1.7 GPa for PA12 — not suitable for high-stiffness applications
  • Poor UV resistance: PP degrades in UV — yellowing, embrittlement after prolonged outdoor exposure. UV stabiliser coating required for outdoor use
  • Lower maximum service temperature than PA12: continuous service limit ~80°C vs ~80°C for PA12 (similar), but PP has lower HDT in some conditions
  • Printing requires N₂ atmosphere in SLS: PP is more sensitive to oxidative degradation during sintering than PA12 — nitrogen purge is non-negotiable
  • Limited post-processing options: PP does not accept most standard adhesives, coatings, and paints without surface activation (plasma or corona treatment) — unlike PA12 which dyes directly

Typical applications

Automotive living hinges: battery covers, under-bonnet clips and straps, snap-fit coversChemical-resistant enclosures: pump housings, valve manifolds, chemical-contact fluid path partsMedical device housings: autoclavable instrument trays, surgical guide holders, point-of-care device shellsSnap-fit connectors and interlocking clip assemblies requiring repeated flex cyclingPackaging prototypes: bottle closures, container lids, custom packaging insertsFood-contact components: storage container prototypes, dispensing mechanismsLaboratory consumable prototypes: sample trays, pipette racks, reagent bottle capsLightweight structural enclosures where lowest possible density is requiredWaterproof housings: PP's low moisture absorption and chemical resistance suits wet environmentsSoft-touch consumer product housings (lower Shore D than PA12)

Industries

automotivemedicalindustrialconsumer

Standards & certifications

ISO-52904established

Process quality assurance for SLS/MJF polymer parts including PP for medical device and chemical-contact applications

medicalindustrial

PP grades intended for medical device or food-contact use require additional compliance: ISO 10993 biocompatibility testing, FDA 21 CFR 177.1520 (PP food contact), or USP Class VI. Autoclavability at 121°C must be validated per ISO 17665 for sterile device applications. HP 3D HR PP has been validated for autoclave cycling — verify with HP application data.

Compatible AM processes (2)

Selective Laser Sintering80–150 µm layersMulti Jet Fusion80–80 µm layers

Other polymer materials

PA12 (Polyamide 12)semi-crystalline thermoplastic polyamidePA12-CF (Carbon Fibre PA12)carbon fibre reinforced polyamide-12 compositePA11 (Polyamide 11)semi-crystalline thermoplastic polyamide (bio-based)PEEK (Polyether Ether Ketone)semi-crystalline high-performance aromatic thermoplasticPEKK (Polyetherketoneketone)semi-crystalline high-performance aromatic thermoplastic (PAEK family)ULTEM 1010 (Polyetherimide PEI)amorphous high-performance thermoplastic (polyetherimide family)PLA (Polylactic Acid)semi-crystalline bio-derived thermoplastic polyesterPETG (Polyethylene Terephthalate Glycol)amorphous/semi-crystalline copolyester thermoplasticABS (Acrylonitrile Butadiene Styrene)amorphous engineering thermoplastic terpolymerTPU (Thermoplastic Polyurethane)elastomeric thermoplastic block copolymerPC (Polycarbonate)amorphous engineering thermoplastic polycarbonateASA (Acrylonitrile Styrene Acrylate)amorphous engineering thermoplastic terpolymerNylon PA6 / PA66 (Polyamide 66)semi-crystalline engineering thermoplastic polyamidePEBA (Polyether Block Amide / TPA)thermoplastic elastomeric polyether block amide copolymer

Related calculators

PackingBuild-chamber utilisation, virgin powder consumption, refresh cost, and cost/part for SLS and MJF. EOS P396, HP MJF 5200/4200, Farsoon 403P presets.Build Time EstimatorPer-process build time from part volume, layer count, and machine throughput. LPBF, SLS, FDM, SLA, DED, binder presets included.Cost-Per-Part EstimatorMachine hourly + material + labor + post-processing → unit cost with margin. Currency-agnostic.RoughnessTheoretical Ra and Rz from layer thickness and surface angle (staircase effect). Upward, downward, and vertical faces. LPBF, SLS, FDM, SLA, DED. Per Grimm et al.Process SelectorNot sure which AM process fits your part? Set material, geometry, quantity, and priorities — ranked, scored list of viable processes with hard exclusion reasons.
Last reviewed: 2026-05-15 · v1 · Sources: wegner-2015-pp-sls, berretta-2014-pp-sls, mazzoli-2013-sls-polymers

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