Fused Granulate Fabrication (FGF) is a large-format additive manufacturing process that is rapidly reshaping what’s possible in 3D printing. Unlike Fused Filament Fabrication (FFF), which uses spooled thermoplastic filaments, FGF relies on pelletised materials—typically thermoplastics or composites—that are melted and extruded layer by layer to create large, durable, and complex parts.
This approach offers advantages in scalability, material flexibility, and cost-effectiveness, making it a preferred option for industries seeking innovative manufacturing pathways.
What Makes FGF Different?
FFF is widely used for small-scale prototyping and consumer products.
FGF is engineered for industrial-scale applications, where speed, size, and custom material properties are critical.
By removing the limitations of filament winding and spooling, FGF unlocks faster build rates, larger object sizes, and access to a wider range of thermoplastics and composites.
Applications Across Industries
Marine: Ideal for manufacturing large objects such as boat hulls, where volume and durability matter.
Tooling and Moulds: Accelerates production of industrial moulds, reducing turnaround times and cost compared to traditional machining.
Construction: Enables production of 3D printed formwork for complex architectural features, streamlining labour and improving precision.
Advantages of FGF
High-Speed Extrusion: Large nozzles deliver rapid material throughput.
Material Versatility: Supports standard thermoplastics (ABS, PLA, PETG) as well as advanced composites with carbon or glass fibre.
Customisation at Scale: Additives like UV stabilisers, flame retardants, or hydrophobic coatings can be integrated for specialised applications.
Sustainability: Facilitates the use of recycled plastics and bio-based polymers, significantly reducing waste and cost.
Cost Efficiency: Pelletised feedstock costs around $4/kg compared to $40/kg for filament, with additional savings available through bulk purchasing.
Challenges and Considerations
Surface Finish: Large nozzles can leave coarse finishes; post-processing such as sanding or machining is often required.
Dimensional Accuracy: Large parts may experience shrinkage or thermal distortion. Optimised cooling and robust support structures help manage this.
Material Consistency: Pellet size and moisture content must be tightly controlled to prevent extrusion defects.
Technical Expertise: Each material requires tailored machine settings, demanding in-depth operator knowledge.
How the FGF Process Works
Pellet Feed – Dry pellets are introduced into a hopper.
Extrusion Screw – Pellets are conveyed through a heated barrel.
Melting and Pressure – Material is melted in multiple heat zones and pressurised.
Layer Deposition – Extrusion follows toolpaths defined by 3D printing software.
This screw-and-barrel system resembles traditional extrusion and injection moulding, making FGF familiar to those in conventional plastics processing.
Machine Types in LFAM with FGF
Robot-Based Systems
Highly flexible, capable of handling complex geometries and large build areas.
Higher cost and technical complexity.
Gantry-Based Systems
Cost-effective and accurate within fixed frames.
Ideal for consistent geometries but with less design flexibility.
FGF vs FFF
Feature | FFF | FGF |
|---|---|---|
Scale | Small to medium objects | Large-scale, industrial components |
Material Range | Limited by filament format | Wide, including recycled and composites |
Cost | ~$40/kg filament | ~$4/kg pellets |
Applications | Prototypes, hobby projects | Marine, construction, tooling, large parts |
FGF surpasses FFF in material freedom, scalability, and cost efficiency, positioning it as the backbone of large-format additive manufacturing.
Looking Ahead
FGF is not simply an incremental improvement over filament-based printing—it represents a fundamental shift in how industries can approach manufacturing. From customised marine structures to sustainable construction solutions, this technology delivers speed, scale, and affordability.
At Hyperion Systems, we’re committed to advancing FGF technology to unlock its full potential across industries. Whether you’re developing innovative moulds, exploring sustainable materials, or tackling large-scale production challenges, our expertise and technology can help bring your vision to life..
