3D printing has come a long way since its early days, and in the recent years it has picked up speed (pun intended)! Yes, if you’ve been keeping track of the industry just over the last couple of years, you would have already the rising number of “high-speed 3D printers” that have been launched. It is actually hard to keep a track of them all now-a-days. (I had actually written an article after the launch of Bambu Lab’s fast 3D printers on how this has ushered in an era of high-speed 3D printing. You can read it if interested).
I am talking about 3D printing speeds ranging anywhere between 200-1000 mm/s. Companies are going crazy on the printing speeds. Take the Bambu Lab P1P for instance, this workhorse can achieve a printing speed of 500mm/s and acceleration of around 20,000 mm/s2.
But here’s the catch: while 3D printers have been busy breaking speed records, the filaments have not kept pace with this development. So, when brands highlight the impressive printing speeds of their machines, you also need to look at what filaments are you going to use on that printer. Certainly not your regular filaments.
That’s where high-speed 3D printing filaments come in. These are specially designed materials that are the right kind of fuel for your fast 3D printers. To leverage the high-speeds, you will need these new filaments.
If you want to know more about these new kinds of filaments, then in this article, we explain all there is to know about it. We’ll explore why they’re becoming essential, how they’re made, and choosing the right kind for your fast 3D printer.
So, buckle up and let’s get (fast) printing!
Need for High-speed 3D Printing Filaments
Whether you’re a tinkerer in your garage or a lecturer looking to teach your students 3D printing or even a small business owner looking to speed up production, understanding high-speed filaments could be the key to taking your 3D printing to the next level. From boosting print quality to slashing production times, these innovative materials are set to revolutionise the way we think about 3D printing.
If you ask, “Why can’t I just use my regular filaments with these speedy new printers?”
Then to answer it, we first need to take a closer look at what happens when we use traditional filaments in high-speed 3D printers.
Think of a regular 3D printer as a standard road car, and a high-speed 3D printer as a high-performance sports car. Both can use similar types of fuel (or in our case, filament), but the high-performance vehicle is designed to operate under more extreme conditions.
Just as a sports car might use a higher-octane fuel to prevent knocking and optimize performance at high speeds, a high-speed 3D printer benefits from specially formulated filaments. These filaments, like higher-octane fuel, are designed to withstand the increased stress and heat generated during rapid extrusion.
When you try to push regular filament through a high-speed printer, it’s like using lower-octane fuel in a high-performance engine. The printer might work, but you’re likely to encounter issues like inconsistent extrusion, poor layer adhesion, or even filament breakage – similar to how a sports car might experience reduced performance or potential engine damage with sub-optimal fuel.
I guess the example was self-explanatory and you have got the idea of why you need a high-speed filament for your high-speed 3D printer.
So, whether you’re looking to churn out prototypes more quickly for your latest project, or you’re just impatient to see your creations come to life, high-speed filaments are becoming less of a luxury and more of a necessity. They’re the missing piece of the puzzle that allows us to truly harness the power of these new, lightning-fast printers. And trust me, once you’ve experienced the difference, you’ll wonder how you managed without them in the first place – the same way you experienced the fast 3D printers.
Impact of High-speed Filaments on Print Quality
When we talk about high-speed 3D printing filaments, it’s not just about printing faster – it should also be about printing better quality. If quality is not considered then the speeds are of no use. And therefore we need to know what impact do these high-speed filaments have on the print quality.
Also, I’ll share this with a caveat that you have to consider this “impact and benefit section” of the article with a pinch of salt. While theoretically the benefits are immense, but practically, not all benefits will be translated in all filaments developed by all brands in all their models. A lot depends on the formulation and I cannot be a spokesperson for all of them. So, please be mindful of this in case you are choosing to buy a high-speed filament.
Improved layer adhesion
First and foremost, high-speed 3D printing filaments can actually improve layer adhesion. These filaments are developed with the fast printing speeds in mind and so they can be extruded at fast speeds. They are formulated in a way that they stick to the build plate and offer a stronger layer adhesion. And everyone knows how important strong layer adhesion is in 3D printing. It is ‘literally’ everything.
Reduced warping and deformation
Another key benefit is reduced warping and deformation. High-speed filaments are also designed to cool down uniformly thereby avoiding the issues like warping and curling.
Enhanced surface finish
Ideally, high-speed 3D printing filaments also offer smoother surface finish. The rapid extrusion and uniform cooling contributes to minimising the layer lines and thereby giving a smoother finish.
Increased print consistency
With traditional filaments, printing at high speeds can lead to inconsistent extrusion – sometimes too much material comes out, sometimes too little. High-speed filaments, however, are formulated to flow consistently even at rapid rates. This means more reliable prints, with fewer blobs, gaps, or other defects.
Manufacturing High-speed Filaments
Engineering high-speed 3D printing filaments requires careful consideration of the factors to be modified. These filaments have to both, melt as well as solidify more rapidly that regular filaments as this allows for faster layer deposition, layer adhesion and quick overall printing speed.
Additionally, the quality and performance also should not be affected and that is where the challenge lies in developing these filaments.
Base Material Selection
Engineering these filaments is still in its infancy and the material performance will depend a lot on the base printing material. Note that high-speed filaments are not some new material, it is an enhanced version of the existing materials through addition of additives or plasticisers, etc. So, the base material plays a crucial role in it printing successfully.
And so, every high-speed filament you see today, is based upon PLA, because PLA is the easiest material to print with. However, as we go forward we will see more and more materials getting optimised for fast printing.
Recently, Bambu Lab launched their fast PETG filament, a first high-speed filament besides PLA.
Material Additives
High-speed 3D printing filaments require a carefully balanced blend of polymers and additives. Manufacturers often start with low-viscosity base polymers, which flow more easily at high extrusion rates. They then add specific flow modifiers to further enhance the material’s ability to be pushed through a nozzle rapidly without causing backpressure or inconsistent extrusion.
Thermal stabilisers
Stabilisers play a crucial role to prevent material degradation during rapid heating and cooling cycles. Some high-speed filaments also incorporate nucleating agents, which promote faster and more uniform crystallisation. This is essential for maintaining dimensional accuracy when layers are deposited in quick succession.
Extrusion Process Modifications
The extrusion process for high-speed filaments is significantly different from standard filament production. Manufacturers use specialised extruders with advanced screw designs that can generate higher shear rates. This helps to reduce the viscosity of the molten polymer, making it easier to extrude at high speeds.
Choosing the Right High-speed 3D Printing Filaments
Breaking down the key factors you need to consider and some tips for getting the most out of these speedy materials.
Printer Compatibility: Not all high-speed 3D printing filaments work with every printer. Check if your machine can reach the high temperatures often required by these filaments – typically around 250-260°C. Also, ensure your printer’s firmware supports the high acceleration and jerk settings needed for rapid printing.
For example, the latest Bambu Lab PETG HF filament needs the nozzle temperature to be between 230-260 °C.
Speed Rating: Do not forget to check the speed rating of these filaments. High-speed filaments often come with a recommended maximum print speed. Some might be optimised for 150mm/s, while others can handle 250mm/s or even more. Match this to your printer’s capabilities and your project’s requirements.
For example, the latest Bambu Lab PETG HF filament is rated for a printing speed of around 300 mm/s.
Layer Adhesion at Speed: Some filaments maintain better layer adhesion than others when printed rapidly. If your project requires high structural integrity, prioritise filaments that specifically advertise strong layer bonding at high speeds. I accept that this is difficult to judge beforehand but in case you want to purchase more of the same material, then you need to consider if your layer adhesion has been good or not. Try out a lot of prints and check for layer issues. Do not think that you made a mistake. The material has to perform and if it does not provide adequate layer adhesion, then do not purchase the same material again, at least until a new version is launched.
Surface Finish: Certain high-speed filaments are formulated to maintain a smooth surface even at rapid print rates. If appearance is crucial, look for options that promise minimal ‘shark skin’ effect or surface roughness at high speeds. You can check out YouTube reviews or blog articles where people might have reviewed the material to neutral reviews.
Check Forums: If you are a hobbyist then you may already be doing this a lot. Forums are the best place to learn real-world use cases. The community will surely post about their experiences with the latest filaments and more often than not you will be able to find a review of the filaments. Do check those out before making the buying decisions.
Tips for Optimal Use
Finally leaving you with some tips for optimal use of these filaments.
Start with the Right Profile: Many high-speed 3D printing filament manufacturers provide specific slicer profiles. Use these profiles as a starting point – they’re often fine-tuned for optimal speed and quality balance instead of directly experimenting with the settings.
Retraction Settings: High-speed printing can exacerbate stringing. You might need to increase retraction speed and distance compared to standard filaments. Some high-speed filaments even benefit from increased retraction prime speed to ensure consistent extrusion after travel moves.
Print Orientation: With rapid printing, overhangs can be more challenging. Orient your model to minimise overhangs, or consider using a high-speed filament that’s specifically designed to handle overhangs well at high print rates.
Temperature Tweaking: While all filament manufacturers will mention the ideal temperature range but still it will be a range and it is advisable that you tune the temperature to suit your 3D printer. You can explore printing temperature towers with 5°C increments to find the sweet spot.
Consider Nozzle Upgradation: Some high-speed filaments perform better with hardened steel or ruby-tipped nozzles, especially if they contain abrasive additives for improved high-speed flow.
Conclusion
If you wanted to explore all about high-speed 3D printing filaments then I hope this article gave you an overall idea about what it is, why it is needed and the impact it can create.
But at the same time this also is a new technology and while you may see that there are some quality issues, or printing issues even in these filaments, so it is important to note that it is not fully mastered yet and it will take some time for it to be as reliable as a regular PLA printing at 60-100 mm/s. So, if you encounter a poor high-speed filament, do not discount it as a gimmick but just think of it as a technology that is yet to be fool proof and in the coming years, it will only get better. You might not be aware but developing high speed 3D printers is harder than you think and similar is the case with its filaments.
If you liked this article, then I’ll kindly request you to please share it on your social media channels and help your connections as well to know about these type of filaments.
