Fused Granular Fabrication (FGF) is an additive manufacturing technique that utilizes unreinforced or reinforced thermoplastic pellets as its primary material. This method provides numerous benefits, particularly in the realm of large-format additive manufacturing (LFAM). FGF is experiencing rapid growth across various industries and has become a leading technology for producing components such as boat hulls and molds for concrete or composite manufacturing. TAFNEX™ Compound, available in a specialized grade for FGF, unlocks vast potential for creating high-performance components suitable for diverse environments.
Pellets are the predominant form of plastic materials, widely utilized in processes like Injection Molding and extrusion. This prevalence ensures a vast availability of materials, far surpassing that of filaments used in fused filament fabrication (FFF).
Pellets are not only more readily available than filaments but also come at a lower cost, thanks to the absence of an additional production phase. They can also be ordered in larger quantities, which leads to a further reduction in costs.
With no requirement for molds and the ability to swiftly change materials, FGF delivers a high level of flexibility. The process involves no physical conversion effort – just a digital change of the component geometry.
FGF stands out among additive manufacturing processes by offering superior scalability for industrial production, thanks to its material availability and high-speed extrusion capabilities.
FGF supports sustainability with the possibility to utilize bio-based and recycled materials. For instance, it can employ compounds derived from recycling thermoplastic composites such as TAFNEX™.
FGF is essentially a mobile version of conventional plastic extrusion, using a typical extruder mounted on a robot or gantry system. Dry pellets are fed into a hopper and moved by an extrusion screw through multiple heating zones, where they melt before being extruded. Controlled by pressure within the extruder, this process follows the contours defined by the software, applying material layer by layer along the component's geometry. The process, depending on the material, is conducted in a sealed, temperature-controlled chamber to ensure layer adhesion, and the printing bed is often temperature-regulated as well. Mechanical post-processing is typically required after FGF manufacturing to achieve smooth surfaces. Some manufacturers provide systems that integrate both additive manufacturing via FGF and subsequent subtractive processes in a single cell.
By using a special grade of TAFNEX™ Compound, hood air duct bezels of a safety car have been produced through Fused Granular Fabrication with the addition of a formed TAFNEX™ Design Sheet for improved aesthetics.
By using a special grade of TAFNEX™ Compound, the fenders of a safety car have been produced through Fused Granular Fabrication with the addition of formed a TAFNEX™ Design Sheet for improved aesthetics.
By using a special grade of TAFNEX™ Compound, elements of a safety car's front bumper have been produced through Fused Granular Fabrication with the addition of formed a TAFNEX™ Design Sheet for improved aesthetics.