3D pellet printing expands manufacturing options and reduces costs compared to FDM printing

The use of 3D pellet printers, which, unlike conventional FDM printers, process pellets instead of filaments, opens up new possibilities in additive manufacturing. Compared to filaments, pellets offer considerable cost advantages and optimized process efficiency.

Dr.-Ing. Bastian Gaedike, CEO of Malping: “3D pellet printers finally offer us the unique opportunity of mapping the properties of conventionally manufactured components in a very cost-effective manner with an additive manufacturing strategy. Tool-based injection molding technology is now being supplemented by a pellet-based 3D printing strategy. I also see further potential for the future: with the newly introduced Voxelfill strategy, 3D printing is now able to reach the strengths of conventional injection molding.”

Gaedike continued: “Malping is a service provider for the additive manufacturing of high-performance thermoplastics. These include PEEK or PEI, known as ULTEM. This market segment is predestined for an additive manufacturing strategy.”

Malping’s strategy includes comprehensive customer support from product design and construction to the validation of the final components. A current project involves the production of a suction ring for the food industry, whose high chemical and thermal resistance results from the glass fiber-reinforced material PPS. This means that the ring can be easily dry-cleaned after use. Thanks to additive manufacturing, individual adaptations can be implemented quickly, which increases the availability of the system for the operator.

The AIM3D ExAM 510 system, which has been on the market since 2022, currently achieves a build speed of up to 150 cm³ per hour and is set to increase to 300 to 600 cm³ per hour in the future. This opens up the potential to process up to 4,000 kg of material per year. The reproducibility of the components is crucial for industrial applications in order to ensure consistent quality. Tests in accordance with DIN EN ISO 527-2 Type 1A show high process stability thanks to the patented pellet extruder technology, which ensures gentle material processing and therefore low polymer degradation values.

“The advantages of an additive solution are obvious in this application: rapid availability of the component starting from component number 1, no tools, possible rapid modification of the component for specific applications on different filling systems. The system operator benefits from a high system availability”, closed Gaedike.

By using materials such as ULTEM 9085 and PEI, 3D pellet printers can now produce components that come close to classic injection molding in terms of performance. This opens up new application possibilities, particularly for the automotive, aviation and mechanical engineering industries.