PLA vs PETG vs ABS Cost Per Gram 2026 — Plus Failure Rates, Strength & When to Use Each
The material you choose affects not just print quality but your cost per gram, failure rate, electricity use, and — critically — your profit margin. This guide compares PLA, PETG, and ABS across every dimension that matters for pricing: cost, failure rate, print difficulty, and what to charge extra for.
Which material should you use?
PLA / PLA+
Default for most prints
Easiest, cheapest, lowest failure rate. Use for decor, display, non-functional items, Etsy products.
PETG
Functional & food-adjacent
Stronger than PLA, moisture-resistant. Use for outdoor items, phone cases, mechanical parts.
ABS
Heat-resistant & post-processable
Highest print difficulty. Use for car parts, high-heat environments, acetone-smoothed display pieces.
Full material comparison — cost, difficulty, and failure rates
| Material | Cost/gram (UK) | Failure rate | Bed temp | Enclosure needed | Sell premium |
|---|---|---|---|---|---|
| PLA | £0.008–£0.015 | 3–5% | 0–60°C | No | — |
| PLA+ | £0.013–£0.020 | 4–6% | 25–60°C | No | Slight (+5–10%) |
| PETG | £0.012–£0.022 | 8–14% | 70–85°C | No (recommended) | Medium (+15–25%) |
| ABS | £0.010–£0.022 | 15–25% | 90–110°C | Yes | High (+20–40%) |
| ASA | £0.018–£0.030 | 12–20% | 90–110°C | Yes | High (+20–40%) |
| TPU | £0.015–£0.035 | 10–18% | 0–60°C | No | High (+25–50%) |
| Resin (standard) | £0.020–£0.050 | 5–10% | N/A | N/A | High (+30–60%) |
Failure rates are community averages for well-calibrated printers. Poor calibration or humidity can double these figures. Use the failure rate calculator to price failure cost into your quotes.
PLA — the default for a reason
Why PLA wins for most sellers
- ✓ Lowest cost per gram — £0.008–£0.015/g for budget brands
- ✓ Lowest failure rate — 3–5% even on open-frame printers
- ✓ No enclosure needed — runs anywhere
- ✓ No warping on most beds with PEI or glue
- ✓ Wide colour range, matte finishes available
PLA limitations
- ✗ Softens above 60°C — not for car interiors
- ✗ Brittle vs PETG or ABS
- ✗ Degrades outdoors over 12–18 months
- ✗ Cannot be acetone-smoothed
PLA+ addresses the brittleness — at only £2–4/kg more it's worth defaulting to for anything functional.
PETG — the upgrade material
PETG costs 20–50% more than PLA per gram but commands a 15–25% price premium from buyers because of its strength and durability story. For functional prints (brackets, phone cases, outdoor fixtures), PETG is almost always worth the switch.
Impact resistance
3–4× stronger than PLA
Heat resistance
Up to 80°C (vs 60°C for PLA)
Moisture resistance
Food-adjacent use possible
PETG pricing tip
PETG has a higher failure rate (8–14%) than PLA. Always add a 10–15% failure buffer to PETG quotes. The failure rate calculator shows exactly how much to add to your selling price.
ABS — charge more, always
ABS has a 15–25% failure rate on most printers without an enclosure. Even with an enclosure (Bambu P1S, X1C), warping and layer separation are more common than with PLA or PETG. Every ABS job should carry a significant failure buffer and a material premium of at least 20–40% over your PLA pricing.
When ABS is worth it
- • Automotive and high-heat environments (80–100°C tolerance)
- • Acetone vapour smoothing for ultra-smooth display pieces
- • Structural parts that need impact resistance AND heat tolerance
When to avoid ABS
- • Open-frame printers — warping will kill your margins
- • High-volume production — failure rate is too costly
- • Beginners — calibrate on PLA first, add ABS later
True cost per print including failure rate — 50g example
| Material | Material cost | Failure adj. (+%) | True material cost | Min sell price (3×) |
|---|---|---|---|---|
| PLA (budget) | £0.60 | 5% | £0.63 | £1.89 |
| PLA+ | £0.90 | 6% | £0.95 | £2.86 |
| PETG | £1.00 | 12% | £1.12 | £3.36 |
| ABS | £0.90 | 20% | £1.08 | £3.24 |
| TPU | £1.50 | 15% | £1.73 | £5.18 |
Min sell price is 3× true material cost only — add electricity, labour, and overhead for your real minimum. Use the full calculator for a complete breakdown.
PLA vs PETG vs ABS — FAQ
Is PETG stronger than PLA?
Yes. PETG is approximately 3–4× stronger than standard PLA in impact resistance, and significantly better at heat resistance (up to 80°C vs 60°C for PLA). PLA+ narrows this gap somewhat, but PETG remains stronger for functional parts.
Which filament has the lowest failure rate?
PLA has the lowest failure rate at 3–5% on well-calibrated printers. PETG runs 8–14%, ABS 15–25%. For commercial printing, PLA's reliability makes it significantly more profitable at volume than ABS even accounting for the price premium ABS can command.
How much more should I charge for PETG vs PLA?
Price PETG prints 15–30% higher than equivalent PLA prints. This covers higher material cost, higher failure rate (add ~10% failure buffer), and the genuine durability premium buyers associate with PETG. Most buyers who specify PETG are building something they care about — they will pay a quality premium.
Can I use ABS without an enclosure?
Technically yes on small prints with aggressive bed adhesion (PEI + glue + draft shield), but expect 15–25% failure rates. The warping and layer separation risk makes ABS commercially unviable on open-frame printers for anything larger than 50mm. Invest in an enclosure (Bambu P1S, X1C, or a DIY enclosure for Ender printers) before offering ABS commercially.
Price any material accurately
Enter your filament type, cost per gram, failure rate, and markup. Get a complete cost breakdown including electricity and recommended sell price.