1100-O (annealed) commercially pure aluminium, Kaiser Aluminum Tube & Pipe Alloy 1100 Technical Data (Rev. 05/06), typical properties; specific heat from Hydro EN AW-1050A (99.5% Al) extruded-products datasheet (10/2018).
BASF Forward AM (BASF 3D Printing Solutions) Ultrafuse HiPS, TDS v2.2 (13.11.2019), printed specimens, XY 'Flat'. Specimen print settings are not stated; recommended processing on the sheet: nozzle 240-260 °C, bed 100-120 °C, 40-80 mm/s. Product is discontinued (Forward AM product page) but the TDS is still served by Forward AM.
Every value links to the document that states it. "Not sourced" means no citable source states it (or only a specification minimum); figures computed from it are left out too.
FDM HIPS is 3D printed: its properties depend on build direction and print settings; these are typical values.
Questions
Is Aluminum 1100-O stronger than FDM HIPS?
Aluminum 1100-O is stronger: its yield strength is 35 MPa against tensile strength 18.4 MPa for FDM HIPS (1.9x).
Which is lighter, Aluminum 1100-O or FDM HIPS?
FDM HIPS is lighter: 1,023 kg/m³ against 2,710 kg/m³ for Aluminum 1100-O.
Which is stiffer, Aluminum 1100-O or FDM HIPS?
Aluminum 1100-O is stiffer: Young's modulus 69 GPa against 1.59 GPa for FDM HIPS, so the same part in Aluminum 1100-O deflects less under the same load.
Which is lighter for the same job, Aluminum 1100-O or FDM HIPS?
For the same stiffness or strength: Aluminum 1100-O is lighter for a stiff rod or tie (tension), stiff beam (bending), stiff panel or plate; FDM HIPS is lighter for a strong rod or tie, strong beam, strong panel or plate.
Part that must be
Aluminum 1100-O
FDM HIPS
Stiff rod or tie (tension)
lighter
16.4x heavier
Stiff beam (bending)
lighter
2.49x heavier
Stiff panel or plate
lighter
33% heavier
Strong rod or tie
39% heavier
lighter
Strong beam
1.73x heavier
lighter
Strong panel or plate
1.92x heavier
lighter
For the same stiffness or strength, mass scales with density over stiffness (or strength) raised to a power set by how the part is loaded: 1 for a rod in tension, 1/2 for a beam in bending, 1/3 for a panel (the standard material-selection indices).
Which conducts heat better, Aluminum 1100-O or FDM HIPS?
Aluminum 1100-O conducts heat better: 222 W/m·K against 0.17 W/m·K for FDM HIPS.
Which expands less with temperature?
Aluminum 1100-O expands less: 23.6 µm/m·K against 80 µm/m·K for FDM HIPS.