Fiber™ is the only composite 3D printer to use Micro Automated Fiber Placement (μAFP)—unlocking exceptional part strength for a desktop printer. Featuring closed-loop heat control, the µAFP tool head deposits low porosity, continuous fiber reinforcement while the FFF printhead enables a high-resolution exterior shell.
Printer
Fiber™ is the only composite 3D printer to use Micro Automated Fiber Placement (μAFP)—unlocking exceptional part strength for a desktop printer. Featuring closed-loop heat control, the µAFP tool head deposits low porosity, continuous fiber reinforcement while the FFF printhead enables a high-resolution exterior shell.
The Fiber™ materials library is categorized by family—or thermoplastic material. Our current library features three material families: Nylon (PA6), PEEK, and PEKK, which can be reinforced by carbon fiber- and fiberglass μAFP tapes.
Materials
Material Family
Chopped Fiber Filament
Continuous Fiber Filament
Material Family
PA6 Nylon
Low cost
High mechanical strength
Continuous Use Temperature ~ 100°C
Chopped Fiber Filament
Carbon Fiber
Fiberglass
Continuous Fiber Filament
Carbon Fiber
Fiberglass
Material Family
PEEK
Excellent mechanical, thermal, and chemical resistance
Excellent resistance to surface abrasion
Flame retardant
Continuous Use Temperature between 200-250°C
Chopped Fiber Filament
Carbon Fiber
Continuous Fiber Filament
Carbon Fiber
Material Family
PEKK
Excellent mechanical, thermal, and chemical resistance
Excellent resistance to surface abrasion
Flame retardant
High compression strength
ESD-Safe
Continuous use temperature above 250°C
Chopped Fiber Filament
Carbon Fiber
Continuous Fiber Filament
Carbon Fiber
Fiberglass: Low-cost, corrosion resistant, non-conductive/insulator, no radio-signal interference.
Carbon Fiber: High strength & stiffness, low coefficient of thermal expansion, high fatigue level, somewhat brittle.
Fiber™ offers users exceptional part quality and a wide range of aerospace and industrial-grade materials—all on a user-friendly, desktop printer.
_Benefits
[01]
Strong parts
Fiber™ combines the exceptional performance of continuous carbon fiber with the ease of FFF printing to produce high-performance parts that are stronger than steel, lighter than aluminum, and can operate continuously in the toughest environments up to 250 ºC.
Continuous carbon fiber or fiberglass tape is applied along critical load paths in a process called Micro Automated Fiber Placement (µAFP). Layers of highly loaded continuous fiber tape are laminated to build dense, reinforced sections over three times stronger than steel and as low as one-fifth the weight (up to 2,400 MPa tensile strength and <1.5 g/cc).
Low porosity
Utilizing continuous fiber tapes made with up to 12k carbon fiber tows or E-glass fiberglass reinforcement, up to 60% fiber volume fraction, and exceptional resin impregnation, Fiber™ is able to achieve continuous fiber reinforcement with less than 1% porosity.
Multi-directional reinforcement
Layers of continuous carbon fiber or fiberglass tape are deposited via µAFP. Users can automatically optimize fiber orientation for maximum coverage, or enable Expert Mode to tailor orientation for specific loading conditions.
_Benefits
[02]
Wide range of materials
Fiber™ prints with two printheads—one dedicated to continuous carbon fiber or fiberglass uAFP tape; one dedicated to chopped carbon fiber or fiberglass-reinforced FFF filament. Designed for versatility, the printer supports a wide range of fiber-reinforced composites to enable a broad set of applications from consumer electronics to automotive.
PEKK is characterized by its high tensile and compression strength, resistance to chemical abrasion and ability to withstand high temperatures (above 250 °C). When reinforced with carbon fiber, the resulting parts are exceptionally durable and safe for operations where ESD compliance is required.
PEEK + Continuous Carbon Fiber
PEEK is characterized by its exceptional mechanical properties. In addition to high resistance to surface abrasion, it is inherently flame retardant, and can withstand high temperatures (above 200 °C). When combined with continuous carbon fiber, the resulting composite is strong, stiff and well-suited for extreme environments.
Nylon (PA6) + Continuous Carbon Fiber
Our PA6 nylon with carbon fiber reinforcement boasts a high fatigue level and a tensile strength 30x stronger than ABS—making it great for high-wear manufacturing jigs and fixtures.
Nylon (PA6) + Continuous Fiberglass
Fiberglass-reinforced nylon is a low-cost material which renders lightweight, high-strength and corrosion-resistant parts—making it ideal for sporting goods applications where parts are exposed to the elements and have a low per-part target cost
_Benefits
[03]
Accessible to all
With a wide range of materials, easy-to-use platform, and affordable pricing, Fiber™ offers high-quality composite 3D printing at a price point every engineer and designer can access.
In a matter of minutes, users can begin 3D printing industrial-grade composites from the comfort of their desktop. Entry-level settings and opt-in advanced controls allow every engineer to produce high-quality composite parts at the press of a button.
Affordable
Boasting superior materials and a large build envelope, Fiber™ offers unrivaled utility at just a fraction of the upfront cost of other industrial continuous fiber composite printers.³ With Fiber™, engineers no longer have to trade between high quality, speed, and affordability.
Material performance
_Strength
Continuous fiber composites exponentially expand the material performance landscape by a factor of over 60x.
— 01
Chopped Fiber
Most thermoplastic printers fall within a narrow range:
— <8 GPa tensile modulus
— <100 MPa strength
Minor enhancements within this range are achieved via modifications to polymers or with the addition of chopped carbon fiber and fiberglass fillers.
— 02
Continuous Fiber
Existing 3D-printed polymer and composite materials only account for a small fraction of engineering needs.
Continuous fiber printing expands this landscape to enable stronger, lighter-weight components.
— Over 75x stiffer than ABS
— Over 60x stronger than ABS
01 - 02
How it works
_Technology introduction
Fiber™ features two printheads—one dedicated to deposition of continuous carbon fiber or fiberglass prepreg tape (μAFP), one dedicated to extrusion of a chopped carbon fiber or fiberglass filament.
— 01
Prep
Generate geometry, review loading conditions, and identify areas for reinforcement.
— 02
Reinforce
Selectively reinforce with continuous carbon fiber or fiberglass μAFP tape along critical load paths.
— 03
Print
The Fiber™ printer utilizes a dual-deposition print method to build parts layer-by-layer in both chopped carbon fiber or fiberglass filament and continuous carbon fiber or fiberglass µAFP tape.
— 04
Part anatomy
Parts printed on Fiber™ feature a chopped fiber shell and solid, continuous carbon fiber or fiberglass reinforcements.
01 - 04
Part Gallery
_Fiber™ applications
Fiber™ applications span a variety of industries including manufacturing, tooling, automotive, consumer, electronics, and marine.
Brake Duct
PEEK + CF
Found on a BMW hill climb car, this duct reroutes air from the front of the car to cool its brakes.
Brake Duct
Size (mm)130 x 63 x 97
Cost ($)54.92
Weight (g)65
Print time (hr)11
Printing on Fiber enables optimization for the most efficient air flow, leading to better cooling. Brakes get extremely hot during competition, PEKK + CF provides heat resistance and is lighter than an aluminum alternative.
Ski Binding
PA6 + CF
The ski binding heel track attaches to the base plate on a ski, allowing the heel binding to be adjusted.
Ski Binding
Size (mm)143 x 57 x 10
Cost ($)6.24
Weight (g)25
Print time (hr)5
Ski bindings need to be extremely stiff to withstand the forces experienced by the ski as it turns, making composites an ideal choice.
Using Fiber™, manufacturers can prototype this part before it is mass produced via injection molding.
Rocket Tail Cone
PEEK + CF
This part sits at the end of a rocket, redirecting air for optimal aerodynamics
Rocket Tail Cone
Size (mm)155 x 155 x 157
Cost ($)297.08
Weight (g)350
Print time (hr)31
This part has to withstand the extreme heat of a rocket engine, so it must be fabricated using a high temperature material like PEEK. With the design freedom of Fiber, engineers were also able to add complex features to improve aerodynamics.
Curling Whip
PA6 + FG
Used in wheelchair curling, this part allows athletes to push curling stones from a seated position.
Curling Whip
Size (mm)129 x 46 x 33
Cost ($)11.24
Weight (g)37
Print time (hr)7
The shape and weight of the whip are critical to the athlete’s performance. Plastic alternatives often break during competition and machined aluminum requires long CNC milling lead times and labor.
Fiber enables the rapid production of custom whip geometry, while continuous fiberglass reinforcement provides a lighter and stiffer alternative to aluminum.
Mirror Mount
PA6 + CF
This part attaches a rear-view mirror to the roll cage on a BMW race car.
Mirror Mount
Size (mm)75 x 97 x 37
Cost ($)6.47
Weight (g)65
Print time (hr)10
Printing this mount on Fiber delivers a part 4X lighter than the original aluminum design, while maintaining strength and durability. In racing, weight is everything, and reducing weight leads to faster times.
Surfboard Fin
PA6 + FG
A hydrofoil mounted on the underside of a surfboard, the fin enables foot-steering and improves stability.
Surfboard Fin
Size (mm)143 x 120 x 6.8 mm
Cost ($)11.05
Weight (g)31
Print time (hr)5
Printing on Fiber enables rapid functional prototyping of the many variables that affect surfboard performance - the fin’s rake, cant, base length, height - and greatly speeds the process when compared to traditional hand layup.
Composites are ideal for this part due to their high strength. In this case, the part is made from PA6 nylon with fiberglass reinforcement to keep costs low and to resist corrosion.
GRIT Lever Connectors
PA6 + FG
A pair of these level connectors are used in custom, all-terrain wheelchairs.
GRIT Lever Connectors
Size (mm)86 x 89 x 47
Cost ($)12.67
Weight (g)78
Print time (hr)12
All-terrain wheelchairs manufactured by Grit are powered entirely by the user - making weight reduction, strength, and stiffness critical to performance. Traditionally machined out of aluminum in custom low quantities, these level connectors typically require a multiple week lead time.
Printing on Fiber in fiberglass-reinforced PA6 enables shorter lead times, reduced weight and greater customization - all while increasing part strength and stiffness.
Balance Shaft Gears
PEKK + CF
This part is a balance shaft gear used in an automotive turbocharger to reduce vibration.
Balance Shaft Gears
Size (mm)117 x 117 x 15
Cost ($)53.37
Weight (g)63
Print time (hr)11
Printing in PEEK delivers a lighter part compared to metal counterparts, while still meeting the strength and heat requirements.
With the ability to print industrial-grade composites like PEEK with continuous carbon fiber reinforcement, Fiber™ allows engineers to print parts that can stand up to high temperatures and have unrivaled part strength - without spending tens of thousands of dollars.
Press Brake Tooling
PA6 + CF
These press brake tools are used to bend aluminum sheet metal.
Press Brake Tooling
Size (mm)95 x 127 x 80, 91 x 64 x 51
Cost ($)162.6, 46.73
Weight (g)364, 105
Print time (hr)33, 11
Many sheet metal applications require custom press brake tooling, but machining this custom tooling out of metal for short runs can be prohibitively expensive.
For low tonnage applications, printing on Fiber eliminates the need for machining costly metal tooling, greatly reducing manufacturing lead time and cost.
Bike Pedal Crank
PA6 + FG
Connecting arm responsible for attaching a pedal to the rear wheel crankset of a bike.
Bike Pedal Crank
Size (mm)205 x 46 x 24
Cost ($)22.82
Weight (g)66
Print time (hr)9
Shedding weight is critical for performance bikes. Composites are an ideal choice for bike components like this due to their high specific strength and stiffness.
Printing on Fiber in fiberglass-reinforced PA6 allows for the manufacture of a corrosion resistant, low cost, functional prototype without the typical labor-intensive process of hand layup.
Assembly Fixture
PA6 + CF
This fixture is used to hold a sheet metal housing while fasteners and electronics are installed.
Assembly Fixture
Size (mm)80 x 61 x 14.3
Cost ($)2.24
Weight (g)15
Print time (hr)3
Assembly fixtures improve consistency and speed operator assembly by holding the work piece in the same location for each unit.
By printing the part on Fiber, the fixture can be manufactured extremely quickly and affordably while still conforming to the exact dimensions of the housing being assembled.
Skydiving Camera Mount
PA6 + GF
This mount attaches a camera to the helmet of a skydiver.
Skydiving Camera Mount
Size (mm)64 x 84 x 14
Cost ($)3.89
Weight (g)16
Print time (hr)3
Glass fiber reinforced PA6 allows for high specific stiffness to withstand those forces at a low cost. This part has to support the weight of the camera while being hit with 100mph+ winds during free fall.
BattleBots Bot Motor Housing
PEEK + CF
Created for a BattleBots, this motor housing was custom-designed to hold an electric motor.
BattleBots Bot Motor Housing
Size (mm)108 x 128 x 24.3
Cost ($)63.68
Weight (g)75
Print time (hr)10
This part holds a motor in place on a combat robot used in the Discovery Channel program, BattleBots. During competition, the bots are subjected to competitors weapons, including saws, axes, and flamethrowers. To withstand the significant stresses and heat, PEEK with Carbon Fiber reinforcement was selected.
On the show, BattleBots teams have very limited time to design and manufacture their bot, so utilizing 3DP is essential. By printing this motor housing, the team was able to get the part in their hands in just a few hours. This allowed them to quickly iterate on the part.
UHF Housing
PEKK + CF
Ultra high frequency radio housing for use in a cubesat.
UHF Housing
Size (mm)95 x 67 x 36
Cost ($)60.51
Weight (g)54
Print time (hr)20.6
Due to the extreme temperatures this part will face in space, this part was printed using PEKK.
Printing this part allowed the cubesat team to quickly iterate on the design in its intended material, and producing multiple variations in a matter of days. The complex geometry and small features of this part make it ideal for printing.
Shroud Holder
PA6 + CF
This fixture is used to hold metal injection molded shrouds for secondary machining operations.
Shroud Holder
Size (mm)143 x 30 x 22
Cost ($)6.71
Weight (g)45
Print time (hr)7
Designed to hold metal injection molded shrouds in place as an articulated robot picks them up and places them in a CNC fixture. This part features customized geometry that conforms to the shrouds’ shape.
Due to their stiffness and wear resistance, composites are ideal for this part.
Heat Shield
PEEK + CF
This heat shield protects the surrounding area of the car from hot exhaust.
Heat Shield
Size (mm)187 x 142 x 83
Cost ($)18.72
Weight (g)22
Print time (hr)5.25
This heat shield can be produced in just a few hours, drastically reducing manufacturing lead time.
The original aluminum heat shield became hot enough to char CF components under the car. PEEK + CF is far less conductive than aluminum, solving this problem and saving weight at the same time.
Machining Fixture
PEEK + CF
This fixture holds lock barrels in place during a secondary reaming operation.
Machining Fixture
Size (mm)212 x 72 x 26
Cost ($)62.31
Weight (g)145
Print time (hr)18
To achieve desired tolerances, metal injection molded (MIM) parts, such as lock barrels, often require secondary machining operations. The fixtures for these operations must be very stiff to hold lock barrels steady while experiencing the forces and vibration of the reamer.
By printing the part on Fiber, the fixture can be manufactured overnight, with similar material properties to aluminum saving both time and money
Rocket Fin
PEEK + CF
Custom rocket fin used for an experimental testing rocket.
Rocket Fin
Size (mm)129 x 48 x 6
Cost ($)22.47
Weight (g)14
Print time (hr)2.5
Fins are critical to keep a rocket stable in flight, but must be custom designed for each rocket to ensure optimal flight. Rather than solely relying on simulations to determine how fins will perform, 3D printing enables designers to create functional prototypes and iterate on geometry based on testing.
With its high specific strength and temperature resistance, carbon fiber reinforced PEKK is an ideal choice of material.
01 - 18
Applications by Industry
_Industries
Explore applications for 3D printing across a range of industries.
Automotive
For automotive manufacturers, 3D printing opens new opportunities for rapid prototyping, creating parts with more complexity than ever before, identifying opportunities for assembly consolidation and exploring new business models centered around on-demand production.
Manufacturers of consumer goods can use 3D printing for rapid prototyping and testing of new designs for both functionality and market feedback, and as a flexible manufacturing line for low-volume and regionally-targeted production that allows greater design freedom for product customization.
By investing in 3D printing, educational institutions provide students the tools to bring their work to life, help them build important career skills and enable them to act as additive manufacturing champions when they enter the workforce.
Using 3D printing, machine designers can print and test multiple part variations, create geometry that cannot be machined, consolidate large assemblies into fewer parts and reduce warehousing costs by printing custom parts on demand.
Heavy industry firms can use metal 3D printing to create highly-customized components from hard-to-machine materials, keep per-part costs low for custom, low-volume parts, and enable the creation of new designs with greater geometric complexity.
For companies that produce manufacturing tooling, 3D printing can be an invaluable resource, allowing them to quickly and inexpensively produce complex, custom tooling and easily replace tools when needed, reducing downtime on manufacturing lines.
¹Fiber™ uses unidirectional uAFP tape, widely considered as one of the highest performance structural materials available and similar to the industrial fiber materials used to manufacture advanced, high-performance parts in a variety of industries, such as aerospace.
²Pricing in US Dollars and may vary by region. Does not include taxes or shipping & handling fees.
³Based on published list prices of comparable industrial continuous fiber composite printers available as of 10.31.2019.
The uses depicted are actual uses by customers based on professionally designed parts using the Fiber™ printer. What you design, print, build, and use is your responsibility. Build responsibly.
™
Fiber™
