Markforged 3D printers have significantly impacted industrial manufacturing by enabling the production of high-strength, functional parts. These systems leverage advanced additive manufacturing techniques, including continuous fiber reinforcement and metal fused filament fabrication, to create components previously unattainable with traditional 3D printing methods. The integration of specialized materials and intelligent software streamlines the entire workflow, from design to final part.
The company’s approach addresses critical engineering challenges, offering solutions for tooling, fixtures, and end-use parts that demand exceptional mechanical properties. By combining robust hardware with sophisticated material science, Markforged provides a compelling alternative to conventional machining for specific applications, reducing lead times and production costs.
Continuous Fiber Reinforcement (CFR) Technology
Continuous Fiber Reinforcement (CFR) is a proprietary Markforged process that embeds continuous strands of high-strength fibers within a thermoplastic matrix. This technique dramatically enhances the mechanical properties of 3D printed parts, making them suitable for demanding industrial applications. CFR-capable machines utilize two extrusion systems: one for the base thermoplastic filament and another for the continuous fiber.
The base material, typically Onyx (a nylon filled with chopped carbon fiber), provides excellent surface finish, heat resistance, and chemical resistance. During printing, continuous fibers like carbon fiber, Kevlar, or fiberglass are strategically laid down within the Onyx matrix, acting much like rebar in concrete. This results in parts that are significantly stronger, stiffer, and more durable than those made from unreinforced thermoplastics.
Carbon fiber, for instance, offers the highest strength-to-weight ratio among Markforged’s reinforcement fibers, often replacing machined aluminum components. Kevlar provides exceptional durability, impact resistance, and a ductile failure mode, making it ideal for parts subjected to repeated or sudden loading. High-Strength High-Temperature (HSHT) Fiberglass maintains strength and stiffness at elevated temperatures, suitable for high-heat applications.
Carbon Fiber 3D Printing Capabilities
| Fiber Type | Key Property | Typical Strength/Stiffness Comparison | Primary Applications |
|---|---|---|---|
| Carbon Fiber | Highest Strength-to-Weight Ratio, Stiff | As strong as 6061-T6 Aluminum, 6x stronger than Onyx | Lightweight components, jigs, fixtures, end-use parts under constant loading |
| Kevlar® | High Durability, Impact & Abrasion Resistance, Ductile Failure | As stiff as fiberglass, more ductile | Parts with repeated loading, shock absorption, protective enclosures |
| Fiberglass | General Purpose Strength, Cost-Effective | 3x stronger, 11x stiffer than ABS | Prototypes, brackets, drill jigs, soft jaws |
| HSHT Fiberglass | High Strength & Stiffness at Elevated Temperatures | Aluminum strength, high heat tolerance | High operating temperature parts, welding fixtures, thermoset molds |
Carbon fiber 3D printing, specifically with Markforged’s CFR technology, produces parts with a strength-to-weight ratio that can exceed 6061 aluminum. This capability allows engineers to design lightweight components that can withstand substantial loads, making them valuable for aerospace, robotics, and automotive applications. The continuous nature of the fiber ensures load distribution across the part’s geometry, preventing localized stress concentrations.
Parts reinforced with continuous carbon fiber exhibit a flexural strength of 540 MPa and a tensile modulus of approximately 60 GPa. This material’s stiffness is a key advantage, as it deflects minimally under stress, unlike aluminum which can plastically deform. Such properties enable the creation of functional end-use parts, jigs, and fixtures that perform reliably in demanding industrial environments.
Metal X System Printing with ADAM Technology
The Markforged Metal X system utilizes Atomic Diffusion Additive Manufacturing (ADAM) technology, a form of metal fused filament fabrication (Metal FFF). This process involves printing metal powder bound in a plastic matrix, which is then debound and sintered to produce dense metal parts. The Metal X system offers a safer and more accessible entry point into metal 3D printing compared to traditional powder-bed fusion methods.
The Metal X printer features a build volume of 300 x 220 x 180 mm and can achieve a layer resolution between 50 and 200 microns. After printing, parts undergo a washing process to remove the binder, followed by sintering in a furnace (Sinter-1 or Sinter-2) at temperatures up to 1300°C. This sintering process fuses the metal particles, resulting in parts with up to 99% dense metal and excellent mechanical properties.
Available materials for the Metal X include 17-4 PH Stainless Steel, H13 Tool Steel, Inconel 625, Copper, and A2/D2 Tool Steel. 17-4 PH Stainless Steel, for example, can achieve an ultimate tensile strength of 1050 MPa (as-sintered) and up to 1250 MPa when heat-treated to H900. H13 Tool Steel offers high hardness and wear resistance, maintaining strength at elevated temperatures, making it suitable for injection molds and extrusion dies.
High-Strength End-Use Parts
Markforged technologies enable the production of high-strength end-use parts across various industries. The ability to embed continuous fibers in composite parts allows for the creation of components that can replace machined aluminum, offering comparable strength with significant weight reduction. This is particularly beneficial for applications like robotic end-of-arm tooling, where minimizing mass is critical for performance.
Metal X printed parts provide robust solutions for high-wear workholding, custom tooling, and functional prototypes. Materials like 17-4 PH Stainless Steel and H13 Tool Steel are utilized for applications requiring corrosion resistance, high hardness, and thermal stability, such as stanchions, cradles, and dies. The precision and material properties achieved allow these parts to integrate directly into production lines, reducing reliance on traditional manufacturing lead times.
Eiger Cloud Software for Optimized Production
Eiger is Markforged’s cloud-based software platform, serving as the central hub for the entire 3D printing workflow. It allows users to upload CAD files, configure print settings, manage material usage, and monitor printer fleets from a single interface. This intuitive slicer software is critical for optimizing part strength, especially for composite prints, by enabling precise control over continuous fiber routing.
The cloud architecture of Eiger facilitates collaboration among engineering teams, allowing remote access and real-time monitoring of print jobs and printer status. It automatically applies material-specific print settings and generates toolpaths, streamlining the process from design to production. Eiger also ensures that printers receive automatic firmware and material updates, keeping the system current with the latest features and capabilities.