The 10 leading 3D printing companies in the composites AM sector

The market for 3D printing with composite materials achieved a growth rate of 21.1% in 2023. The total value of the market has increased from USD 648 million in the previous year to USD 785 million. These figures come from a recently published report “Composites AM Market 2024” by VoxelMatters Research.

A key driver of this development is the hardware sector, which recorded a jump in sales from USD 278 million to USD 330 million. This represents growth of 18.5%. However, the materials sector also showed strong momentum with an increase from USD 148 million to USD 187 million (+26%). Services, particularly through AM service bureaus, also recorded growth of 21.2%, from USD 221 million to USD 268 million.

The report also lists the top 10 companies in this sector:

1. Markforged

The largest company in terms of revenue is Markforged. It emerged less than a decade ago from the open-source filament material extrusion 3D printing segment with its unique CFF (Continuous Fiber Fabrication) technology. Today, Markforged is a public company with revenues of around $94 million in 2023. CFF technology combines thermoplastic filament with continuous fiber to create high-strength composite parts. Markforged’s industrial-grade printers, such as the X-Series, use CFF to produce parts that have exceptional strength, stiffness, and durability. These printers can utilize materials like carbon fiber, fiberglass, and Kevlar. In addition to industrial solutions, Markforged also offers desktop printers. The Mark Two and Mark One (Onyx Pro) desktop printers feature CFF technology and support materials like Onyx (carbon fiber-filled nylon). These printers are used for educational purposes, prototyping, and small-scale production. The base version, Onyx One, supports only chopped carbon fiber materials.

2. Stratasys

Over 30 years ago, Scott Crump, the founder of Stratasys, invented FDM (the first-ever filament material extrusion technology). Through several acquisitions, Stratasys has become the world’s largest 3D printing company in terms of annual revenue. Today, Stratasys offers a range of 3D printers across five different technological categories. In 2018, the company introduced the Fortus 380mc Carbon Fiber Edition, its first FDM system dedicated specifically to carbon-fiber-filled Nylon 12. As part of its transition to the F-line brand, Stratasys now offers the F123CR Series composite 3D printers, in addition to the F190CR and F370CR systems. This composite-ready printer family builds on the simplicity of the F123CR Series printers to provide carbon-fiber 3D printing for more demanding applications.

3. EOS

EOS, a German company founded by Dr. Hans J. Langer, leads the industrial SLS 3D printing market and is therefore also a leader in the composites SLS segment. EOS is the only company that has introduced advanced systems for high-performance composite PEKK powders, such as the EOS P 810. Although this system is not aggressively marketed, it is notable as it can process the EOS HT-23 PEKK polymer from Arkema to create parts that can withstand temperatures well above 200 °C. Composite specialist Hexcel also offers the HexAM service for making composite PEKK parts using modified EOS systems, leveraging a proprietary process acquired from Oxford Performance Materials (OPM).

4. HP

Since the launch of MJF technology in 2016, HP has focused on high-throughput production for parts. To achieve this, HP worked on developing an optimized workflow. As production rates increased, the complexities of the workflow evolved significantly in the next-generation HP Jet Fusion 5200 systems. Today, the company’s hardware supports one composite material, the HP 3D High Reusability PA 12 Glass Beads. This material is a 40% glass bead-filled thermoplastic material with high stiffness and reusability. Currently, this material is only available on the 5200 and 4200 platforms.

5. Airtech

Airtech has emerged as the leading supplier of pellet materials for LFAM technologies. After larger companies such as SABIC and Techmer divested from this market segment due to its limited size, Airtech filled the gap by establishing partnerships with leading LFAM hardware developers worldwide, including companies like Caracol and CMS. Airtech has developed a series of innovative composite resins (ABS, PETG, PC, PEI, PESU) under the Dahltram brand for use in large-scale 3D printing. These resins address the need for lower CTE and increased durability when used at both low and high temperatures, including in an autoclave. They are designed for use in any pellet-fed material extrusion 3D printing system.

6. 3D Systems

3D Systems has been a major first-party provider of 3D printing composite powders for its SLS platforms, including carbon fiber-reinforced and glass-reinforced nylon powders, as well as mineral-filled nylon powders. More recently, the company entered the LFAM segment with the acquisition of the US-based company Titan and is now becoming an increasingly relevant supplier of composite materials in pellet form.

7. Ingersoll

Along with Cincinnati Incorporated (which has now exited the segment) and Thermwood, Ingersoll was among the first companies to develop LFAM systems. The company, belonging to the Italian Group Camozzi, sells machines in both North America and Europe and can leverage its extensive expertise in the high-end CNC system to produce very large machines with price tags of over 1 million dollars. Recently, the LFAM market has grown significantly and new players have emerged such as CMS in the gantry-based segment, as well as several other operators in the robotic LFAM segment.

8. Materialise

Materialise is one of the largest AM service providers globally, with a sizable installed hardware presence across various technologies. While Chinese companies may have more systems installed, Materialise produces a greater number of parts due to higher demand and its extensive expertise in AM. They primarily offer composite 3D printed parts using PBF technology, specifically SLS (EOS machines) and MJF (HP machines), as well as FDM parts produced using Stratasys machines. Although LFAM services are currently not available, Materialise remains the largest composite AM service provider in terms of revenues.

9. MCPP

Mitsubishi Chemical Performance Polymers (MCPP) is a division of Mitsubishi Chemical Corporation that specializes in performance polymers. In 2018, MCPP acquired Dutch Filaments, a filament supplier based in the Netherlands. This acquisition allows MCPP to develop and market a wide range of composite filament materials, including engineering, high-temperature, and recycled filaments, as well as pellets for large-format AM. Their 3D printing range features raw materials sourced from LEHVOSS and DSM/Covestro.

10. SABIC

SABIC is a chemical manufacturing company that operates as a subsidiary of Saudi Arabian-owned oil and gas company Saudi Aramco, following an acquisition agreement in 2019. They are a leading producer of various plastic materials, such as polyolefins, polypropylene, and polyethylene. In recent years, SABIC has also ventured into manufacturing 3D printing polymers, including high-performance ULTEM thermoplastic filaments. SABIC specializes in creating special compounds for large-format additive manufacturing through their THERMOCOMP AM product line. These materials are designed specifically for large-format, pellet-fed extrusion systems and are based on four of SABIC’s amorphous resins: ABS, PPE, PC, and PEI.

The Composites AM 2024 market report is over 250 pages and contains 140 charts and data tables focusing on all the technologies and materials used in additive manufacturing of composites to produce prototypes, tooling and end-use parts across several key industry segments including industrial, automotive, consumer goods, aerospace, design and energy. The report costs £4,490 and can be ordered here.