GAME CHANGER

High Performance 3D Printing

Latest Trend

Reshaping carbon-fiber 3D printing

A new range of high-temperature carbon-fiber composite filaments is being developed for Fused Filament Fabrication (FFF) 3D printing. With the addition of these products to the KyronMAX® family, Mitsubishi Chemical Advanced Materials aims to demonstrate the potential of directly 3D printing carbon-fiber composite parts, while still benefiting from the properties of the high-strength material.

Unbeatable Strength and Compatibility

Fused Deposition Modeling (FDM)

The composite filaments integrate chopped carbon fibers into a thermoplastic matrix. This matrix can be composed of different thermoplastic materials, including high-temperature thermoplastics, such as, Nylon, PPA, PEKK, and PEEK , all of which will be offered as part of Mitsubishi Chemical Advanced Materials’s standard Fused Deposition Modeling (FDM) materials portfolio. Each matrix offers its own set of unique properties when combined with fiber reinforcement. Mitsubishi Chemical Advanced Materials is backward integrated into carbon fiber and has the ability to not only adjust the dimensions of the carbon fiber itself but also the ‘adhesion layer’ on the carbon fiber to make it compatible with a specific thermoplastic matrix, adding to the strength of the material and the final part.

KyronMAX® Additive Manufacturing Properties

Download the Material Properties table PDF [62.8 kB]
High Performance 3D Printing

How could we support scaling your production - Your journey from prototype to high-volume production

Number of Parts

1-10

Manufacturing Technology

Functional prototyping and small series

Design Freedom

Very high

Volume (#parts)

Low

Upfront investment (Tool)

Very low

Speed

<1 week

Size part

Small –Medium

Material

All, KyronMAX®

Description

3D Printing (FDM or FFF) of a visual/ functional part.

Number of Parts

1-10

Manufacturing Technology

Functional prototyping and small series

Design Freedom

Very high

Volume (#parts)

Low

Upfront investment (Tool)

Very low

Speed

<2 week

Size part

Small –Medium

Material

All, KyronMAX®

Description

SPRINT (Soluble Printed Injection Tooling) is based on AddiFab's Freeform Injection Molding technology. It provides the flexibility of 3D printing (of the mold) with injection molding quality. It enables the production of small series parts that are 100% functional and can be scaled at low risk to high volume injection molding. Max size of the printed mold 96x54x150mm. Up to 4 molds can be combined to expand the build envelope.

Number of Parts

1-100

Manufacturing Technology

Machining (CNC)

Design Freedom

Moderate

Volume (#parts)

Low – Medium

Upfront investment (Tool)

Low

Speed

2 weeks

Size part

Small –Medium

Material

Limited by degree of fillers or very soft materials

Description

Customization of plates, rods or near net shapes.

Number of Parts

10-1000

Manufacturing Technology

Near net injection molding + Machining (CNC)

Design Freedom

Moderate

Volume (#parts)

Low – Medium

Upfront investment (Tool)

Medium

Speed

2 weeks

Size part

Small – Very large

Material

Limited by degree of fillers or very soft materials

Description

Cost effective way of production by combining injection molding of near net shape (NNS) in combination with machining for adding features and creating very tight tolerances.

Number of Parts

100-10,000

Manufacturing Technology

Injection molding – Machined aluminum tool

Design Freedom

Low - moderate

Volume (#parts)

Low – Medium

Upfront investment (Tool)

Medium

Speed

4 – 6 weeks

Size part

Small – Very large

Material

All, KyronMAX®

Description

Conventional injection molding.

Number of Parts

100-250,000

Manufacturing Technology

Injection molding – 3D printed metal insert in mother tool

Design Freedom

Moderate

Volume (#parts)

Medium – High

Upfront investment (Tool)

Medium

Speed

<6 weeks

Size part

Medium

Material

All, KyronMAX®

Description

Injection molding with a 3D printed metal insert. Max size is approx. 250x250x250 mm.

Number of Parts

>10,000-1 Million

Manufacturing Technology

Injection molding – Hardened Steel tool

Design Freedom

High

Volume (#parts)

High

Upfront investment (Tool)

High

Speed

10 – 24 weeks

Size part

Low – Medium

Material

All, KyronMAX®

Description

Complete hardened tool with moving parts.

Number of Parts Manufacturing Technology Design Freedom Volume (#parts) Upfront investment (Tool) Speed Size part Material Description

1-10

Functional prototyping and small series

Very high

Low

Very low

<1 week

Small –Medium

All, KyronMAX®

3D Printing (FDM or FFF) of a visual/ functional part.

1-10

Functional prototyping and small series

Very high

Low

Very low

<2 week

Small –Medium

All, KyronMAX®

SPRINT (Soluble Printed Injection Tooling) is based on AddiFab's Freeform Injection Molding technology. It provides the flexibility of 3D printing (of the mold) with injection molding quality. It enables the production of small series parts that are 100% functional and can be scaled at low risk to high volume injection molding. Max size of the printed mold 96x54x150mm. Up to 4 molds can be combined to expand the build envelope.

1-100

Machining (CNC)

Moderate

Low – Medium

Low

2 weeks

Small –Medium

Limited by degree of fillers or very soft materials

Customization of plates, rods or near net shapes.

10-1000

Near net injection molding + Machining (CNC)

Moderate

Low – Medium

Medium

2 weeks

Small – Very large

Limited by degree of fillers or very soft materials

Cost effective way of production by combining injection molding of near net shape (NNS) in combination with machining for adding features and creating very tight tolerances.

100-10,000

Injection molding – Machined aluminum tool

Low - moderate

Low – Medium

Medium

4 – 6 weeks

Small – Very large

All, KyronMAX®

Conventional injection molding.

100-250,000

Injection molding – 3D printed metal insert in mother tool

Moderate

Medium – High

Medium

<6 weeks

Medium

All, KyronMAX®

Injection molding with a 3D printed metal insert. Max size is approx. 250x250x250 mm.

>10,000-1 Million

Injection molding – Hardened Steel tool

High

High

High

10 – 24 weeks

Low – Medium

All, KyronMAX®

Complete hardened tool with moving parts.

Case Study - 3D Printing

Sorting Wheel

How does the relative production cost compare to CNC Machining and 3D Printing (FFF, Fused Filament Fabrication) of a sorting wheel like?

Learn about how SPRINT (Soluble Printed Injection Tooling) could facilitate smooth scaling of your product in this case study.

Download case study PDF [392.5 kB]
Case Study - 3D Printing

Assembly Collet

What is the relative production cost in comparison between CNC Machining and 3D Printing (FFF, Fused Filament Fabrication) of an assembly collet?

Learn how 3D Printing (FFF) of the assembly collet resulted in an astonishing 87% reduction of material usage in this case study.

Download case study PDF [470.4 kB]
Advanced Manufacturing Technologies

Fused Filament Fabrication (FFF)

Mitsubishi Chemical Advanced Materials offers an extensive range of manufacturing technologies, in which 3D printing (FFF) offers several advantages compared to conventional manufacturing methods:

Lower cost: 3D printing eliminates the need for expensive tooling, minimizes material waste compared to subtractive processes, and has no minimum order quantity (MOQ)

Design freedom: 3D printing enables product designers and engineers to design more lightweight parts (lattices, honeycomb structures), to consolidate multiple parts into a single structure, and to produce previously impossible designs

Production agility: 3D printing reduces part development time by eliminating steps in the prototyping workflow, can simplify shipping and logistics with distributed manufacturing, and can be used to produce emergency replacement parts on demand.

How Startups and Entrepreneurs innovating with 3D printing technology?

Inspiring stories from the winners of High-temperature carbon-fiber 3D Printing Challenge held in December 2021. In this challenge, the participants were asked to incorporate the strength and properties of the KyronMax® carbon-fiber 3D printing filament with the flexibility and sustainability of 3D printing in their design. 

Read the stories