3D Printing and the Future of Filaments
Published: September 18, 2025 · Reading time: 3 minutes
Introduction
3D printing, or additive manufacturing, has evolved from a prototyping tool into a powerful production technology that is reshaping industries. Unlike conventional manufacturing methods such as injection molding or machining, 3D printing builds objects layer by layer, offering unmatched design freedom, rapid iteration, and minimal material waste. This makes it ideal for custom components, complex geometries, and small production runs where traditional processes may be costly or impractical.
While the printers themselves often take center stage, the filament, the feedstock material used in fused filament fabrication (FFF), is just as critical to the performance and final properties of the printed part. The choice of filament defines not only how easily a part can be printed, but also its mechanical strength, thermal stability, chemical resistance, and appearance.
Filaments in the Market Today
The range of commercially available 3D printing filaments has expanded significantly in the past decade. Common options include:
- PLA Poly(lactic Acid): Biodegradable, easy to print, widely used in prototyping and educational applications.
- ABS (Acrylonitrile Butadiene Styrene): Tough and heat-resistant, suitable for functional parts.
- PETG Poly(ethylene Terephthalate Glycol): Combines good strength with easier processing compared to ABS.
- Nylon (Polyamide): Strong, flexible, and wear-resistant, often used in mechanical parts.
- Filled filaments: Enhanced with carbon fibers, glass fibers, or metal particles to improve stiffness, conductivity, or aesthetics
In addition, engineering plastics such as PEEK (Polyetheretherketone), PEI (Ultem™), and Poly(phenylene Sulfide) are now entering the 3D printing market. These materials offer exceptional performance, high thermal stability, chemical resistance, and mechanical strength, making them attractive for aerospace, automotive, and medical applications. Processing these polymers, however, requires advanced extrusion and handling due to their higher melting temperatures and sensitivity to moisture.
The Need for New Filaments
As industries adopt 3D printing for functional components, the demand for new, application-specific filaments continues to grow. High-performance applications require materials that go beyond today’s commodity polymers: aerospace looks to engineering plastics like PEEK or PEI for lightweight, heat-resistant parts; medical devices demand biocompatible and sterilizable filaments; electronics seek conductive or antistatic filaments; and sustainability initiatives drive the need for bio-based or recycled feedstocks.
Developing these novel filaments is not straightforward. It requires controlled compounding, dispersion of additives or reinforcements, and extrusion into consistent filament feedstock. Small-scale R&D tools are essential to accelerate this process, enabling researchers to test formulations without the cost and material consumption of industrial-scale extrusion.
Enabling Custom Filament Development
The Xplore 3D Filament Line is a benchtop extrusion system designed for the controlled production of polymer filaments at laboratory scale. When coupled with Xplore micro-compounders, it provides a direct workflow from formulation to filament manufacturing, enabling systematic evaluation of new materials.
Technical Features:
- Operates with small sample quantities (tens of grams), suitable for experimental polymers and engineering plastics.
- Extrusion parameters can be precisely controlled, ensuring consistent filament diameter and reproducibility.
- Capable of processing filled and reinforced formulations (e.g., carbon fibers, conductive additives, bio-based fillers).
- Facilitates rapid material screening, allowing researchers to link formulation variables to filament properties and printability directly.
Figure 1. Diagram of a 3D printing process
Conclusion
3D printing continues to transform how products are designed and manufactured, but the technology’s full potential depends heavily on the materials that feed it. While today’s filament portfolio offers a strong foundation, the next wave of innovation will require custom-engineered filaments, including high-performance engineering plastics with properties tuned for demanding applications.
With benchtop processing tools like the Xplore 3D Filament Line, researchers can quickly and efficiently explore new formulations, bridging the gap between laboratory-scale material design and industrial 3D printing performance.