Digital ABS is a PolyJet digital material: two rigid photopolymers with complementary properties are jetted together in a fixed microstructure and cured by UV light in the same build. The resulting composite simulates standard-grade ABS in stiffness and impact behavior much better than single rigid PolyJet materials, while keeping PolyJet's fine detail and smooth surfaces. An oven cycle after printing, called thermal post-treatment, raises the heat deflection temperature at 0.45 MPa from about 58–68 °C to about 82–90 °C.
Choose Digital ABS for functional prototypes that need more toughness and heat resistance than standard PolyJet: snap-fit and assembly tests, housings and enclosures, parts that are handled or dropped during evaluation, and inserts for short injection-molding trial runs. It remains a photopolymer, not a thermoplastic. It does not reach the impact strength or long-term stability of molded ABS, it ages under UV light, and it creeps under sustained load. For end-use parts, choose machined, molded or powder-bed printed thermoplastics.
Mechanical and physical properties
| Property | Typical value | Notes |
|---|---|---|
| Tensile strength | ≈ 55–60 MPa | ASTM D638, printed test bars. |
| Elongation at break | ≈ 25–40% | Clearly higher than rigid opaque PolyJet (≈ 10–25%). |
| Tensile modulus | ≈ 2.6–3.0 GPa | Somewhat stiffer than molded ABS. |
| Flexural strength | ≈ 65–75 MPa | ASTM D790. |
| Notched Izod impact | ≈ 90–115 J/m | ASTM D256. About four times rigid opaque PolyJet; below molded ABS (≈ 150–400 J/m). |
| HDT at 0.45 MPa, as printed | ≈ 58–68 °C | ASTM D648. |
| HDT at 0.45 MPa, after thermal post-treatment | ≈ 82–90 °C | Oven cycle after printing; can distort thin or long parts. |
| HDT at 1.82 MPa | ≈ 51–55 °C | As printed; relevant for parts under load. |
| Hardness | ≈ 85–87 Shore D | Hard surface. |
| Density | ≈ 1.17–1.18 g/cm³ | Cured material; heavier than ABS (≈ 1.04–1.06 g/cm³). |
Typical datasheet values for Digital ABS, measured on printed test bars. Real parts vary with wall thickness, orientation, print mode, post-treatment and age. The toughness depends on the composite structure forming fully, which needs adequate wall thickness, and photopolymers keep changing with UV exposure and time.
Designing for Digital ABS
Digital ABS follows the general PolyJet rules: overhangs and cavities are built on a support material that is removed after printing, and very thin layers give fine detail. Its composite structure and intended functional use add a few points:
- Wall thickness: walls of about 1.2 mm and more are recommended for full toughness. For thinner walls, grade variants designed for thin sections exist; state thin-wall areas so the grade can be confirmed in the quote.
- Snap fits and clips: use generous root radii and moderate deflection, and validate the design on a print. Digital ABS is tougher than rigid PolyJet but less forgiving than molded ABS.
- Threads and inserts: printed threads suit occasional assembly. For repeated assembly, use press-fit or bonded inserts in prepared holes.
- Flat and long parts: thermal post-treatment can warp thin, long or flat parts. Ribs and uniform walls help; mark features that must stay flat.
- Glossy or matte: faces that touch support come out matte. Orient cosmetic faces upward, or ask for an even matte finish.
- Mold inserts: inserts for trial molding runs need generous draft, no thin standing features and a design agreed with the molder. Tool life is short and depends on the molded plastic, its temperature and the geometry.
Thermal post-treatment
Thermal post-treatment is a controlled oven cycle after printing and support removal. It raises the HDT at 0.45 MPa from about 58–68 °C to about 82–90 °C. It adds a process step and time, and thin or long parts can distort, so state in the order whether the treatment is required and which features are flatness-critical. Without it, plan for Digital ABS to soften above about 55–60 °C.
Tolerances and surface
Without a tolerance on the drawing, Uretyco's default for PolyJet parts is ±0.2 mm or ±0.2%; tighter values apply only when they are stated on the drawing and accepted in the quote. Thermal post-treatment can shift dimensions and flatness on thin or long parts. Surfaces are smooth with fine detail, as with other PolyJet materials. Bores and fit-critical faces can be reamed or machined after printing if they are marked on a drawing.
Finishing options
Digital ABS parts are often used as printed. Finishing serves mainly appearance, fits and heat resistance.
| Finish | Effect | Notes |
|---|---|---|
| As printed, matte or glossy | Lowest cost | Faces that touched support are matte; upward faces can be glossy. |
| Sanding and polishing | Smoother, even surface | Removes support marks on cosmetic faces. |
| Primer and paint | Exact color, production look | Digital ABS comes in a few fixed colors; paint for an exact color match. |
| Drilling, reaming and tapping | Accurate holes and threads | Mark holes and fits on a drawing. |
| Inserts | Durable threads for repeated assembly | Press-fit or bonded inserts in prepared holes. |
| Thermal post-treatment | HDT ≈ 82–90 °C at 0.45 MPa | Adds time and can distort thin or long parts. |
Digital ABS narrows the gap to molded ABS but does not close it. Test snap fits, drops and warm environments on printed samples, and keep the final production material in mind when you interpret the results.
Cost and lead-time drivers
Digital ABS costs more than single rigid PolyJet materials, because it combines two materials in a dedicated print mode:
- Part volume, bounding box, orientation, support material and machine time, as for all PolyJet parts.
- The two-material composite itself, which costs more than a single rigid material.
- Thermal post-treatment, sanding, painting, reaming and inserts, each adding a step.
- Dense, bulky parts that could be hollowed, split or redesigned.
- Lead time: small parts can be fast; thermal post-treatment, painting and mold-insert reviews add time.
Digital ABS vs. other functional prototype options
| Material and process | Toughness | Heat resistance | Surface and detail | Typical use |
|---|---|---|---|---|
| Digital ABS (PolyJet) | Good for a photopolymer (Izod ≈ 90–115 J/m) | HDT ≈ 58–68 °C; ≈ 82–90 °C after post-treatment | Excellent | Tough, detailed functional prototypes |
| PolyJet rigid opaque | Low; brittle (≈ 20–30 J/m) | HDT ≈ 45–50 °C | Excellent; colors and multi-material | Visual and color models |
| SLA tough resin | Moderate to good; grade-dependent | HDT ≈ 45–65 °C, grade-dependent | Excellent | Lower-cost tough resin prototypes |
| ABS (FDM) | Good along layers; weaker across them | ≈ 80–100 °C | Visible layer lines | Low-cost prototypes in real ABS |
| PA12 (MJF, SLS) | Very good | ≈ 80–100 °C | Slightly grainy | Durable functional parts and small series |
Digital ABS sits between visual PolyJet models and real thermoplastic parts. Choose it when a detailed prototype must survive assembly, snap fits or drops. Choose FDM ABS when the real material matters more than surface quality, and PA12 when parts must work mechanically over time or in small series.
When not to choose Digital ABS
End-use parts that need the long-term properties of ABS: use molded or machined ABS. Sustained load, especially when warm, because photopolymers creep. Service above about 55–60 °C without thermal post-treatment, or above about 80 °C with it. Outdoor use or long UV exposure. Very thin walls where full toughness cannot develop. Food, skin or medical contact: Digital ABS is not certified for it; biocompatible PolyJet grades are separate materials.
Typical applications
- Snap-fit, clip and assembly prototypes.
- Housings and enclosures for electronics and consumer products.
- Functional prototypes that are handled, dropped or tested in use.
- Mold inserts for short injection-molding trial runs with common thermoplastics.
- Light-duty jigs, fixtures and gauges.
- Unloaded parts for warm environments up to about 80 °C, after thermal post-treatment.
Specifying Digital ABS on Uretyco
- 1Upload STL, 3MF or STEP
STEP helps the review of fits and mold inserts. Add a PDF drawing for holes, threads and critical dimensions.
- 2Choose PolyJet and Digital ABS
State the color if it matters; Digital ABS comes in a few fixed colors.
- 3State temperature and post-treatment needs
Give the operating temperature, whether thermal post-treatment is required, and which features must stay flat.
- 4Describe the use
Tell the assistant whether the part is a snap-fit test, an enclosure, a drop test or a mold insert, so materials and processes can be compared.
- 5Review the quote
Feasibility, grade, post-treatment, finishing and lead time are confirmed during quote and order review.
FAQ
Is Digital ABS the same as ABS?
No. It is a cured photopolymer composite that simulates the stiffness and toughness of ABS, not the thermoplastic itself. It cannot be melted or welded like ABS, its impact strength is below molded ABS, and it ages under UV light. It is a good stand-in for prototypes, not for end-use parts.
Do I need thermal post-treatment?
Only if the part will see temperatures above about 55–60 °C during testing or use. The treatment raises the HDT to about 82–90 °C at 0.45 MPa but adds time and can distort thin or long parts. State the operating temperature in the order so the need can be confirmed.
Digital ABS or standard rigid PolyJet?
Choose standard rigid materials for visual models and for color or multi-material parts. Choose Digital ABS when the part must flex, snap or survive drops: its notched impact strength is about four times higher. It costs more and comes in fewer colors.
Can Digital ABS be used for injection-mold inserts?
Yes, for short trial runs with common thermoplastics, when molding conditions are adapted to a printed tool. Tool life is limited and depends on the plastic, its temperature and the geometry, so plan the insert together with the molder. Longer runs use machined aluminum or steel tooling.
Related resources
- PolyJet Rigid OpaqueVisual, color and multi-material models.
- Tough Resin (SLA)Impact-resistant SLA prototypes.
- ABSThe thermoplastic that Digital ABS simulates.
- PA12 (Nylon 12)Durable powder-bed functional parts.
- Injection MoldingFrom prototypes to molded parts.
- 3D PrintingTechnologies, files, tolerances and cost drivers.
Related materials
Plastics
PolyJet Clear
Rigid, near-colorless acrylic photopolymer jetted in very thin layers. Polished, it becomes clear enough for see-through housings, light-guide mock-ups and flow models. It is brittle and softens at about 45–50 °C, so it does not suit optics or loaded parts.
Plastics
PolyJet Rigid
Rigid, UV-cured acrylic photopolymer jetted in very thin layers. Very smooth surfaces, fine detail, color and multi-material options for visual prototypes and master patterns; not meant for load-bearing or hot parts.
Plastics
PolyJet Bio
Rigid clear or opaque PolyJet photopolymers tested for biocompatibility, used for surgical guides, dental devices and skin-contact prototypes. Compliance depends on the certified grade, the validated process and the device maker's own regulatory work.
Plastics
Tough Resin
Engineering photopolymers formulated to behave like ABS or polypropylene: far more impact- and fatigue-tolerant than standard resin, with the same smooth surface and fine detail. For snap-fits, enclosures, jigs and functional prototypes at room temperature.
Elastomers
PolyJet Rubber-like
Flexible photopolymer jetted alone or mixed with rigid material to reach about 30–95 Shore A. Suited to overmold-style prototypes, soft-touch grips and seals for fit tests; low tear strength and aging limit it to prototypes.
Plastics
ABS
Tough, low-cost, easy-to-machine and paintable thermoplastic. The default for indoor housings, covers and look-like prototypes; not for UV, heat or solvents.
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