PLA vs PETG vs ABS: Filament Cost vs Use Case
Filament choice affects material cost, electricity cost, and failure rate simultaneously. Here is how to match material to application — and what each choice costs you per kilogram at the printer.
Choosing a filament is not just about material properties. Temperature requirements, failure rates, and post-processing time all affect the real cost per successful print. Here is how the three most common FDM filaments compare when you account for the full picture.
PLA: the sensible default
PLA (polylactic acid) prints at 180–220 °C with a 60 °C or unheated bed. It is the most forgiving filament for first-layer adhesion, produces minimal warping, and rarely needs an enclosure. For sellers and hobbyists, these properties translate directly into lower failure rates and lower machine running costs.
Cost per kilogram: £15–25 for standard PLA, £20–35 for PLA+ (slightly toughened formulation). Print temperature is lower, so electricity cost per print is marginally less than PETG or ABS.
Limitations: PLA softens at around 60 °C. It is unsuitable for car interiors, outdoor use in direct sun, or anything that will be exposed to sustained heat. It is also more brittle than PETG under impact.
PETG: the production workhorse
PETG (polyethylene terephthalate glycol-modified) prints at 230–250 °C with a 70–90 °C bed. It is significantly more impact-resistant than PLA, has better UV resistance, and handles heat up to around 80 °C. For practical parts — brackets, clips, tool holders, anything that takes force — PETG is usually the right choice.
Cost per kilogram: £18–30. Roughly comparable to PLA but you will spend more on electricity per print due to higher temperatures. More importantly, PETG is unforgiving of moisture; print with wet filament and you get bubbles, stringing, and surface defects. A filament dryer (£25–50) is almost essential for high-volume PETG use.
Failure rate consideration: PETG strings aggressively if retraction settings are not dialled in. Expect more calibration time than PLA, and build that into your cost model for new material or machine setups.
ABS: when you need heat resistance
ABS (acrylonitrile butadiene styrene) prints at 230–250 °C and requires a heated bed at 100–110 °C and typically a fully enclosed chamber. Without an enclosure, thermal contraction during printing causes layer separation and warping, especially on large flat parts.
Cost per kilogram: £15–25, similar to PLA. But the real cost driver is the electricity for a heated enclosure and the higher failure rate without one. ABS also emits volatile organic compounds during printing — adequate ventilation is necessary.
ABS is mainly justified when you need parts that survive 100 °C+ environments (engine bay components, electronics enclosures near heat sources) or when you need to acetone-smooth a print to a gloss finish.
ASA: the outdoor alternative
ASA (acrylonitrile styrene acrylate) offers similar heat resistance to ABS with much better UV resistance and slightly easier printing. For outdoor applications, ASA has largely replaced ABS in professional settings. Cost is similar: £20–30/kg.
Matching material to job
For most decorative and display prints: PLA. For functional parts at room temperature: PETG. For high-heat or outdoor applications: ASA. For complex geometries needing smooth finish: ABS with acetone post-processing.
When quoting for clients, factor the material uplift into your pricing — PETG and above typically add £0.30–0.80 per print in material and electricity versus an equivalent PLA print, before accounting for higher failure rates during calibration.