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COMPOSITE 3D PRINTING


With world's first composite 3D printer capable of printing capable of printing continuous strand of  Carbon Fiber, Fiberglass and Kevlar® into high quality Nylon , 3D Prototyping is not capable of printing incredible strong parts.

With choice of special reinforcement materials , parts , tooling and fixers with a higher strength-to-weight ratio than 6061-T6 Aluminum, a higher abrasion resistance and best strength-to-cost can be printed. 

High end materials options are:

  • Onyx - Nylon mixed with chopped carbon fibre
  • Carbon Fibre – Highest strength to weight.
  • Fiberglass – Highest strength to cost.
  • Kevlar® – Abrasion resistance. (additional information to come)
  • HSHT-High Strength High Temperature 
  • Nylon – Tough engineering plastic.

Onyx

Onyx is a chopped carbon fiber reinforced nylon.  It is 1.4 times stronger and stiffer than ABS and can be reinforced with continuous fiber such as Carbon Fiber, Fiberglass , HSHT and Kevlar®. Onyx sets the bar high for surface finish,chemical resistivity and heat tolerance. The Flexural strength is 81 MPa and the Heat Deflection Temperature is 145°.

              

Carbon Fibre CFF Filament

Prints like plastic, but stiffer than aluminum. This patent pending composite is 20x stiffer than ABS and is stronger than Al 6061-T6 by wieght. Cabon Fibre CFF™ is perfect for fixture , jigs and parts that need the highest strength-to-weight ratio.

Carbon Fibre:

  • Best strength-to-weight
  • Stiffer than 6061 Al


Fiberglass CFF Filament

Fibreglass filament is the perfect alternative when the strength of Carbon Fibre Filament is needed, but the stiffness and weight are less critical. This patent pending Fibreglass CFF filament uses the same Continuous Filament Fabrication process for impressive strength, but at a much lower cost.

Fibreglass:

  • Best strength-to-cost
  • Electrically Insulating

Kevlar CFF Filament

Kevlar filament is a tough and hard like material five times as strong as steel! Kevlar has many applications, ranging from bicycle tyres, racing sails to body armour because of its high tensile strength-to-weight ratio; It is also used to make modern drumheads that withstand high impact and even underwater applications.

Kevlar:

  • high tensile strength-to-weight ratio;
  • 5 times stronger than steel, temperate resistance

HSHT  Fibreglass Filament

High Strength High Temperature(HSHT) exhibits aluminium strength and high heat tolerance.It is 5 times stronger and 7 times stiffer than Onyx. It is best suited for parts to be used in high temperature application.


              

Nylon CFF Filament

Fantastically flexible, but tough as nails. This nylon filament has great fatigue and impact resistance. Nylon is also a great outer protective layer to keep your fixtures and tooling from scratching sensitive parts. It’s also a great choice for tabs, clips, and mechanical fasteners.

Nylon:

  • Tough engineering plastic
  • Low-friction
  • Flexible

SPECIFICATIONS:

Printing Technology:

  • Fused Filament Fabrication (FFF)
  • Composite Filament Fabrication (CFF)


Build Size:

  • 320mm x 132mm x 160mm (12.6″ x 5.2″ x 6.3″, 412ci)


Material Compatibility:

  • Onyx , Carbon Fiber, Fiberglass, HSHT, Kevlar®, Nylon


Highest Layer Resolution:

  • FFF Printing: 100 Microns
  • CFF Printing: 200 Microns

Anatomy of a Composite Filament Fabrication Part

3D Prototyping can help accelerate your design cycle. Printed parts add incredible strength to traditional FFF parts by reinforcing them with embedded continuous strand composites using the Composite Filament Fabrication™ (CFF™) process. This example shows a 3D printed functional prototype “foot” for an Aeromotions wing that is capable of producing 860 lb. of downforce at 200mph. Our unique software will allow added reinforcement where you need it, creating a robust, fibre reinforced part.

1. Nylon base + 3 carbon fibre layers

The nylon base provides a tough, non-abrasive outer shell. Next, three layers of carbon fibre are added to provide strength. In this example, we’re using 3 x 200 micron layers of carbon fibre on the top and bottom for a total of 6 layers.

2. Nylon honeycomb structure

The software automatically generates the honeycomb core between the composite layers. This sandwich panel construction enables great efficiency in part weight and cost.

3. Final Carbon Fibre CFF + nylon case

The top layers of carbon fibre reinforcement are printed, capped off with a few layers of nylon – no post curing or vacuum bagging required.


For further information, please explore our FAQ, or contact us on the form below.

Composite 3D Printing Enquiry Form