Large format Fused Granular Fabrication (FGF) 3D printing has transformed manufacturing by enabling the production of large-scale parts using polymer granules instead of filaments. This analysis examines the most common materials in FGF printing using standardized criteria for direct comparison.
FGF (Fused Granulate Fabrication) 3D printing is a process that uses granules or pellets of thermoplastic material, which are melted and extruded layer by layer to create a 3D object. It’s known for offering a wider range of materials and faster printing compared to traditional filament-based methods. FGF is particularly well-suited for large format 3D printers, as it allows for the use of bulk material in pellet form, making it more cost-effective and efficient for printing large-scale objects.
Material Properties and Processing Parameters
For each material, we examine the following standardized criteria:
Processing temperature range
Material cost per kilogram
Processing rate (throughput)
Mechanical properties (tensile strength, impact strength)
Environmental conditions (chamber temperature, drying requirements)
Density
Moisture sensitivity
Warpage tendency
Layer adhesion strength
Chemical resistance
ABS (Acrylonitrile Butadiene Styrene)
ABS remains a cornerstone material in FGF printing, with typical processing temperatures ranging from 230°C to 250°C. Modern FGF systems can process ABS at rates of 2-15 kg/hour, depending on the nozzle diameter and print parameters. The material costs typically range from $2.20 to $3.50 per kilogram for industrial-grade pellets.
Processing Temperature: 230-250°C
Material Cost: $2.20-3.50/kg
Processing Rate: 2-15 kg/hour
Tensile Strength: 45 MPa
Impact Strength: 320 J/m
Chamber Temperature: 45-60°C
Drying Requirements: 4-6 hours at 80°C
Density: 1.04 g/cm³
Moisture Sensitivity: Moderate (0.2-0.3% absorption)
Warpage Tendency: High
Layer Adhesion: 85-95% of injection molded
Chemical Resistance: Moderate
PP (Polypropylene)
Polypropylene has gained significant traction in FGF printing due to its chemical resistance and low density. Processing temperatures typically range from 200°C to 230°C, with throughput rates of 3-18 kg/hour on industrial FGF systems.
Processing Temperature: 200-230°C
Material Cost: $1.80-2.70/kg
Processing Rate: 3-18 kg/hour
Tensile Strength: 35 MPa
Impact Strength: 150 J/m
Chamber Temperature: 30-40°C
Drying Requirements: Not required
Density: 0.91 g/cm³
Moisture Sensitivity: Low (<0.1% absorption)
Warpage Tendency: Very High
Layer Adhesion: 80-90% of injection molded
Chemical Resistance: Excellent
PETG
Polyethylene Terephthalate Glycol is one of the most common materials in additive manufacturing. It is completely fumeless while still having great formability and durability.
Processing Temperature: 235-255°C
Material Cost: $2.40-3.80/kg
Processing Rate: 2.5-12 kg/hour
Tensile Strength: 50 MPa
Impact Strength: 280 J/m
Chamber Temperature: 40-50°C
Drying Requirements: 4-8 hours at 65°C
Density: 1.27 g/cm³
Moisture Sensitivity: High (0.4-0.5% absorption)
Warpage Tendency: Low
Layer Adhesion: 90-98% of injection molded
Chemical Resistance: Good
Recycled PETG
Using recycled PETG is a great way to focus on sustainability and keep material costs down. It has emerged as a popular choice, but still has different properties than PETG, and may be more difficult to work with. Current data shows:
Processing Temperature: 235-255°C
Material Cost: $1.20-2.00/kg
Processing Rate: 2.5-12 kg/hour
Tensile Strength: 42 MPa (85% of virgin)
Impact Strength: 238 J/m (85% of virgin)
Chamber Temperature: 40-50°C
Drying Requirements: 6-10 hours at 65°C
Density: 1.27 g/cm³
Moisture Sensitivity: Very High (0.5-0.6% absorption)
Warpage Tendency: Low to Moderate
Layer Adhesion: 75-85% of injection molded
Chemical Resistance: Good
Glass Fiber Reinforced PP (30% GF)
Glass fiber can make materials very strong and stiff while keeping its ductility. This material category offers enhanced mechanical properties:
Processing Temperature: 220-260°C
Material Cost: $4.50-6.00/kg
Processing Rate: 2-10 kg/hour
Tensile Strength: 85 MPa
Impact Strength: 95 J/m
Chamber Temperature: 40-50°C
Drying Requirements: 2-4 hours at 80°C
Density: 1.12 g/cm³
Moisture Sensitivity: Low (0.1-0.2% absorption)
Warpage Tendency: Moderate
Layer Adhesion: 70-80% of injection molded
Chemical Resistance: Excellent
Carbon Fiber Reinforced ABS (20% CF)
Carbon fiber reinforced materials are usually on the high-performance end of FGF printing. This is one of our most recommended materials for large volume 3D prints as it has great bed adhesion and is much easier to work with than other materials.
Processing Temperature: 240-280°C
Material Cost: $8.00-12.00/kg
Processing Rate: 1.5-8 kg/hour
Tensile Strength: 75 MPa
Impact Strength: 280 J/m
Chamber Temperature: 50-70°C
Drying Requirements: 6-8 hours at 80°C
Density: 1.08 g/cm³
Moisture Sensitivity: Moderate (0.2-0.3% absorption)
Warpage Tendency: Low
Layer Adhesion: 70-85% of injection molded
Chemical Resistance: Moderate
Processing Considerations
The success of FGF printing depends heavily on proper material handling and processing conditions. Each material requires specific attention to:
Moisture Control: Most materials, except PP, require careful moisture management. Recycled materials typically need longer drying times due to higher moisture absorption rates.
Temperature Management: Chamber temperature control is crucial for all materials to prevent warpage and ensure proper layer adhesion. Higher-performance materials generally require higher chamber temperatures.
Wear Considerations: Fiber-reinforced materials cause increased wear on printing components, particularly nozzles, with typical wear rates of 0.1-0.2mm per 1000kg of processed material.
Economic Implications of FGF Materials
Material selection significantly impacts the economics of FGF printing. Virgin materials offer the most consistent properties but at higher costs. Recycled materials provide cost savings of 40-60% but require additional processing steps and quality control measures. Fiber-reinforced materials command premium prices but deliver enhanced mechanical properties necessary for structural applications.
The standardization of these parameters allows for direct comparison between materials and helps in selecting the most appropriate material for specific applications. The choice of material should balance processing requirements, mechanical properties, and economic considerations based on the intended use case.
In most cases, printing with pellets greatly reduces the cost in comparison to traditional filament. See how else they compare here.
