What's the Best 3D Printing Material for Motorsport Parts?

Choosing the Right FDM 3D Printing Material at Mullan Racing

Material selection is one of the most important decisions in the entire 3D‑printing process. The geometry might define the shape, but the material defines the performance, strength, stiffness, heat resistance, durability, sustainability, and how the part behaves in the real world.

At Mullan Racing, we focus on a tight, well‑understood set of engineering‑grade materials so we can guarantee predictable, repeatable results. Most of our FDM materials are recycled or bio‑based, but we also have materials from virgin stock for when that top performance is required.

To make selection easier, we group our materials into clear tiers and compare them using real datasheet values, so we can choose based on numbers, not guesswork.

 

PLA (Polylactic Acid) Tier

PLA is the most common FDM material, even though it is weak, brittle and can melt in the sun, it plays a big role in engineering materials. It is perfect for getting mock-ups made, before you commit to a big run in more exotic materials. We use PolyTerra PLA by Polymaker mainly for their policy of planting a tree for every spool sold, couple that with the fact PLA is a bio-plastic it is very sustainable. We normally print mock-up parts in white so during test fit we can write directly on the part easily for quick design iteration notes.

PLA Tier Use Cases

• Mock-up parts
• Demonstration models
• Trinkets

 

PCTG (Polycyclohexylenedimethylene Terephthalate Glycol) Tier

PCTG is your baseline engineering material: tough, stable, and predictable. Our baseline PCTG is available in a lot of colours making it great at those parts where clear identification is key. The CF (carbon filled) variant adds stiffness and a great surface finish giving it that high grade engineering feel. Another great property of baseline PCTG is the layer adhesion makes the parts near isotropic, opening up the design possibilities.

PCTG Tier Comparison Table
Property	PCTG by Nobufil	PCTG CF by Nobufil	Summary
Density	1.23 g/cm³	1.28 g/cm³	CF is slightly denser
Tensile Strength	48 MPa	60 MPa	CF is stronger
Flexural Modulus	1700 MPa	3100 MPa	CF is stiffer
Elongation at Break	74%	7%	Base PCTG is more ductile
Impact Strength (notched)	2 kJ/m²	1.3 kJ/m²	Base PCTG is tougher
HDT (0.45 MPa)	65°C	72°C	CF increases temp range
Sustainability	Recycled	Recycled	Both sustainable
Notable Strengths	Tough and accurate	Stiffer and stronger

 

PCTG Tier Use Cases

• Pit equipment
• Garage hardware
• Jigs
• Moulds
• Housings
• Identification parts
• Tools

 

PC (Polycarbonate) Tier

This tier covers the step up from PCTG into true engineering materials. PC blends offer stiffness, heat resistance, and impact strength. Our PC CF by Spectrum sits at the top as the performance benchmark. But with the release of PCx CF by Nobufil we are pleased to offer a sustainable option at this level. All our PC filaments are CF (carbon filled) composites which compliments the properties of PC well.

PC Tier Comparison Table
Property	PCx CF by Nobufil	PC CF by Spectrum	Summary
Density	1.23 g/cm³	1.22 g/cm³	Both similar
Tensile Strength	68 MPa	76 MPa	PC CF is stronger
Flexural Modulus	3500 MPa	2354 MPa	PCx CF is stiffer
Elongation at Break	11%	Higher than PCx CF*	PC CF is more ductile
Impact Strength (notched)	4.5 kJ/m²	6.9 kJ/m²	PC CF is tougher
HDT (0.45 MPa)	113°C	140°C	PC CF is more heat resistant
Sustainability	Recycled	Petro‑based	PCx CF is sustainable
Notable Strengths	Sustainable and stiff	Sustainability traded for performance

*Spectrum state >100% on their TDS.

PC Tier Use Cases

• Structural parts
• Ducts
• Aerodynamic parts
• Jigs
• Tools

 

Nylon (Polyamide) Tier

If you need the strongest, stiffest, most heat‑resistance in our engineering materials, this is the tier. PA12 CF15 by Fiberlogy leads in stiffness and strength, setting the standard. PA11 CF by prusament brings excellent heat resistance making it a great sustainable option. PA12 GF15 by Fiberlogy is rugged ready for harsh environments. We keep unfilled PA12 by Fiberlogy for pure nylons ductile and low‑friction properties, when parts need sliding mechanisms for example.

 

Nylon Tier Comparison Table
Property	PA12 CF15 by Fiberlogy	PA11 CF by Prusament	PA12 GF15 by Fiberlogy	PA12 by Fiberlogy	Summary
Density	1.07 g/cm³	1.11 g/cm³	1.13 g/cm³	1.01 g/cm³	PA12 is lighter
Tensile Strength	120 MPa	61 MPa	72 MPa	45 MPa	PA12 CF15 is stronger
Flexural Modulus	7000 MPa	6200 MPa	3600 MPa	1400 MPa	PA12 CF15 is stiffer
Elongation at Break	5%	3.30%	8%	50%	PA12 is more ductile
Impact Strength (notched)	15 kJ/m²	17 kJ/m²	16 kJ/m²	12 kJ/m²	All filled filaments are tougher
HDT (0.45 MPa)	170°C	192°C	175°C	135°C	PA11 CF can handle the highest heat
HDT (1.8 MPa)	150°C	152°C	165°C	55°C	PA12 GF15 can handle more heat under high load
Sustainability	Petro‑based	Bio‑based	Petro‑based	Petro‑based	PA11 CF is sustainable
Notable Strengths	Top stiffness and strength	Sustainable and good heat resistance	Tough and better chemical resistance	Low‑friction, high‑ductility

 

Nylon Tier Use Cases

• Structural parts in high temperatures
• Ducts in high temperatures
• Rigid aerodynamic parts
• Durable housings
• Sliding mechanisms
• Jigs in high temperatures

 

Flexible Tier

Materials define performance, this is truest of all in this tier. These range from soft cushioning foams to tough elastomers and chemically resistant rubbers.  Our supplier Recreus dominates this space with a well‑structured range. Filaflex 82A by Recreus is our go to for flexibles, it is super tough almost with an indestructible feel, and available in a range of colours. Reciflex by Recreus is a great sustainable alternative for Fileflex 82A if no colour options and a slight increase in hardness is acceptable for the application. Filaflex Foamy by Recreus is a specialised material which can achieve a varied hardness foam structure, its more delicate than the other materials in this tier, but is lightweight and excellent for cushioning. Filaflex SEBS by Recreus is chemically resistant perfect for unique seals and gaskets.

Flexible Tier Comparison Table
Property	Filaflex 82A by Recreus	Filaflex Foamy by Recreus	Filaflex SEBS by Recreus	Reciflex by Recreus	Summary
Density	1.12 g/cm³	1.05 → 0.709 g/cm³	0.906 g/cm³	1.00–1.22 g/cm³	Foamy is lightest
Hardness	82A	78A → 51A	90A	92–98A	Foamy softest; Reciflex firmest
Tensile Strength	45 MPa	37 MPa	Not specified by manufacturer	40–50 MPa	82A & Reciflex are strongest
Elongation at Break	650%	740%	146%	>400%	Foamy & 82A extremely elastic
Tear Strength	70 N/mm	Not specified by manufacturer	73.5 N/mm	Not specified by manufacturer	82A & SEBS high tear resistance
Abrasion Resistance	25 mm³	Not specified by manufacturer	230 mm³	Not specified by manufacturer	82A best abrasion resistance
Vicat Softening Temp	113°C	94°C	113°C	Not specified by manufacturer	82A & SEBS best for heat
Chemical Resistance	Good	Good	Excellent	Good	SEBS best for chemicals
Hydrolysis Resistance	Excellent	Good	Good	Excellent	82A & Reciflex best in wet environments
Notable Strengths	Extremely elastic and tough “indestructible feel”	Lightweight and cushioning	Chemical and environmental resistance	Sustainable and tough

 

 

Flexible Material Use Cases

• Flexible joints
• Protective covers
• Vibration buffers
• Custom bump rubbers
• Seals and gaskets
• Custom compliance interfaces
• Soft protective housings

 

Specialist Tier

In some cases we are looking for very specific properties in materials, like flame retardant and ESD (Electrostatic Discharge). For parts that need to be flame retardant we use PPS CF10 by Polymaker. PPS (Polyphenylene Sulphide) is naturally V0 UL94 rated and it is also no slouch, with good metal-like stiffness and heat resistance. When parts need to be made for protecting sensitive electrical components we go to PA612 ESD by Polymaker. A member of the Nylon family PA612 ESD is a great material for any situation its tough and strong with great heat resistance, protecting sensitive components to the end with its carbon nano tube filler.

 

Specialist Tier Comparison Table
Property	PA612 ESD by Polymaker	PPS CF10 by Polymaker
Density	1.1 g/cm³	1.29 g/cm³
Tensile Strength	84 MPa	59.4 MPa
Flexural Modulus	3745 MPa	4646 MPa
Elongation at Break	3%	1.40%
Impact Strength (notched)	5.9 kJ/m²	5.3 kJ/m²
HDT (0.45 MPa)	157°C	252°C
HDT (1.8 MPa)	125°C	133°C
Sustainability	Petro‑based	Petro‑based
Notable Strengths	ESD properties with good mechanical and thermal properties	V0 UL94 rated with good mechanical and thermal properties

 

 

In This Together

Sometimes looking at all this data can feel overwhelming. But that’s why we are here to help, we will guide you through material selection through the quote and design process. We try to focus on using sustainable materials where possible, but whatever you need to solve your problem we will try to facilitate. Even if your needs require material we don't stock, we will work with our suppliers to meet your needs. Get in touch and together lets print to win!