Carbon Fiber Reinforced Filaments

Carbon fiber reinforced materials are filled with continuous fibers or fiber particles that result in parts with improved physical properties and high stiffness. There is a variety of carbon fiber reinforced options out there for 3D printing, but they all require drastically different print settings.

Carbon fiber-reinforced filaments combine the benefits of thermoplastics with the strength and stiffness of carbon fibers, creating materials optimized for engineering-grade applications. These composites are ideal for lightweight, durable parts requiring enhanced mechanical properties and dimensional stability.

What Are Carbon Fiber-Reinforced Filaments?

Carbon fiber filaments infuse short carbon fibers into a base thermoplastic (e.g., PLA, PETG, Nylon, ABS, or PC). The fibers increase rigidity, reduce warping, and improve heat resistance while maintaining the printability of the base material.

Key Benefits

• Increased Stiffness: Fibers enhance rigidity, reducing flex in structural components.

• Dimensional Stability: Minimizes shrinkage and warping during cooling.

• Lightweight: Lower density than metals, ideal for weight-sensitive industries.

• Improved Heat Resistance: Higher heat deflection temperatures than base materials.

Common Carbon Fiber-Reinforced Options

1. PLA-CF

• Base Material: PLA

• Properties: Enhanced stiffness and surface finish, but reduced layer adhesion and impact resistance.

• Applications: Aesthetic prototypes, drone frames, lightweight fixtures.

• Limitations: Brittle; unsuitable for high-stress or high-temperature environments.

Polymaker's PLA-CF

2. PETG-CF

• Base Material: PETG

• Properties: Balances rigidity with UV/chemical resistance; less prone to warping than ABS-CF.

• Applications: Automotive trim, outdoor fixtures, functional prototypes.

• Limitations: Reduced ductility compared to standard PETG.

3. Nylon-CF (e.g., NylonX, PA-CF)

• Base Material: Nylon (PA6/PA12)

• Properties: High tensile strength (up to 100 MPa), heat resistance (HDT up to 155°C), and fatigue resistance.

• Applications: Jigs, gears, aerospace brackets, and under-hood automotive parts.

• Limitations: Requires rigorous drying and abrasion-resistant hardware.

Polymaker's Fiberon™ PA6-CF20

4. ABS-CF

• Base Material: ABS

• Properties: Improved stiffness and reduced warping compared to standard ABS.

• Applications: Automotive prototypes, enclosures, and functional components.

• Limitations: Prone to fumes; requires ventilation.

5. PC-CF

• Base Material: Polycarbonate

• Properties: Exceptional strength (tensile ~70–75 MPa) and heat resistance (up to 150°C).

• Applications: Aerospace components, high-temperature fixtures, and electrical insulators.

• Limitations: Demands high nozzle temperatures (300–330°C) and enclosed printers.

6. Specialty Composites

• PPS-CF: High thermal stability (up to 260°C short-term) for aerospace and chemical-resistant parts.

• PP-CF: Lightweight with fatigue resistance for hinges and snap-fit assemblies.

Printing Considerations

Hardware Requirements

• Nozzle: Hardened steel, ruby, or diamond-coated to withstand abrasion.

• Bed Adhesion: PEI sheets, adhesives (e.g., Magigoo), or textured surfaces.

• Enclosure: Recommended for warping-prone materials (e.g., ABS-CF, Nylon-CF).

Challenges

• Abrasion: Accelerated wear on extruder gears and Bowden tubes.

• Moisture Sensitivity: Nylon-CF and PC-CF require drying (70–80°C for 4–6 hours).

• Layer Adhesion: Higher nozzle temps and slower speeds improve bonding.

Applications by Industry

Industry	Use Cases	Preferred Materials
Aerospace	Brackets, ducting, drone frames	Nylon-CF, PPS-CF, PC-CF
Automotive	Mounts, trim, under-hood components	PETG-CF, ABS-CF, Nylon-CF
Industrial	Jigs, conveyor parts, tooling	Nylon-CF, PC-CF
Consumer	Phone cases, sporting goods	PLA-CF, PETG-CF
Medical	Prosthetics, surgical guides	Nylon-CF (biocompatible)

Pros and Cons

Advantages

• Strength-to-Weight Ratio: Lighter than metal with comparable rigidity.

• Dimensional Stability: Reduced warping for precision parts.

• Aesthetic Appeal: Matte finish with visible fiber texture.

Limitations

• Brittleness: Reduced impact resistance in some formulations (e.g., PLA-CF).

• Cost: More expensive than standard filaments.

• Hardware Wear: Abrasive fibers necessitate frequent nozzle replacements.