Pellet-based 3D printing (FGF – Fused Granulated Fabrication) is currently one of the most significant evolutions in extrusion-based additive manufacturing. Direct access to pellets overcomes the limitations imposed by filament, enabling the processing of complex technical compounds, filled materials, and custom formulations, often specifically developed for industrial or R&D applications, where material validation is an integral part of the product development process.
In this article, the comparison between Indart3D, a developer of pellet-based printing systems for R&D activities, and LATI3Dlab, a manufacturer of engineered compounds for additive manufacturing, provides a concrete technical perspective on the joint evolution of machines and materials in industrial 3D printing.
Pellet-based 3D printing: the perspective of application developers
What led to the founding of Indart3D and the choice of pellet-based 3D printing?
We began manufacturing Tumaker 3D printers in 2013, initially working with filament-based systems. About ten years ago, we decided to focus on pellet-based printing, which at the time was less widespread and more complex, but showed clear potential for added value. This decision led to the development of our first pellet-based 3D printers.
Around 2020, we introduced some of the first small-scale machines capable of combining filament and pellet extrusion within the same system. Since then, our focus has progressively shifted toward solutions predominantly based on pellet processing.
What limitations of filament-based printing drove the shift toward pellet processing?
Over time, we were increasingly contacted by customers interested in processing materials not available in filament form: highly elastic materials, compounds with high ceramic loadings, or formulations that are difficult—if not impossible—to convert into filament. This demand clearly highlighted the need for an alternative to filament-based printing.
Who uses pellet-based 3D printing systems today?
Our main customers are universities, research centers, and industrial R&D departments across various sectors. These users are looking for systems that allow them to work directly with their own materials, which is exactly the value proposition we offer.
Beyond supplying the machines, we train users so they can work independently, understand material behavior, and identify the limits and opportunities of each formulation. This approach is particularly relevant in research, development, and material validation contexts.
What trends are driving the evolution of pellet-based 3D printing?
The development of pellet-based 3D printing is progressing along multiple directions. On one hand, it enables the production of large-scale components with material throughput in kg/h significantly higher than filament-based systems, using pellets that are more cost-effective and available in a much broader range.
On the other hand, we are seeing strong growth in material customization, the use of advanced technical compounds, and closer integration between material manufacturers and 3D printing system developers.
Small-scale systems also play a strategic role, as they allow the development and testing of formulations specifically designed for 3D printing using limited material quantities. In this context, the use of recycled materials represents a significant opportunity in terms of both sustainability and circular economy.
Why choose LATI3Dlab for pellet-based 3D printing applications?
In this application context, material selection becomes a determining factor.
The choice of LATI3Dlab materials is driven by both technical and strategic considerations. From a technical standpoint, we were looking for materials with stable formulations, good behavior in pellet extrusion, and reliable mechanical properties, even in non-conventional printing environments.
From a business perspective, we value the ability to offer innovative, well-documented materials that are clearly oriented toward real industrial applications. Using LATI3Dlab compounds allows us to demonstrate to our customers the potential of advanced technical materials in additive manufacturing.
Materials for pellet-based 3D printing: LATI3Dlab’s technical response
We now move into a detailed discussion of the technical characteristics of the selected material, exploring with Francesco Manarini, Product Development Manager at LATI, the formulation and printability aspects of the grade LATENE EP 3 AM K/20.
What characteristics make LATENE EP 3 AM K/20 suitable for pellet-based 3D printing?
The formulation is designed to ensure good interlayer adhesion and controlled warpage, which are typical challenges of polyolefins in both filament- and pellet-based 3D printing.
How are stiffness, dimensional stability, and interlayer adhesion balanced?
An effective balance was achieved through the careful selection of raw materials—base polymer, reinforcing fibers, processing additives, and modifiers—supported by years of laboratory testing and mechanical and rheological studies.
What advantages does it offer in terms of processability and process reliability?
Like all materials in the AM range, specifically engineered by LATI3Dlab for FFF and FGF 3D printing, these formulations ensure high repeatability thanks to:
- “Locked” raw materials within the formulation
- Strictly controlled and consistent process parameters
- Quality controls specifically designed for compounds dedicated to additive manufacturing
In which applications does the material deliver the greatest value?
LATENE EP 3 AM K/20 is able to deliver high levels of chemical resistance, typically associated with higher-end polymers such as PPS, PPA, or PEEK, while maintaining a more economically accessible positioning.
The material is also insensitive to moisture, ensuring excellent processability and consistent repeatability regardless of environmental conditions or storage history.
For a complete analysis of the compound’s mechanical, chemical, and processing properties, the material technical data sheet is available.
[Download the LATENE EP 3 AM K/20 technical data sheet]
FAQ – Pellet-based 3D printing and technical materials
What is pellet-based 3D printing (FGF)?
It is an additive manufacturing technology that uses plastic pellets instead of filament, enabling the direct use of technical compounds and custom materials.
What advantages does it offer compared to filament-based 3D printing?
Greater freedom in material selection, lower raw material costs, and the ability to process filled or experimental formulations.
Which materials are best suited for pellet-based 3D printing?
Engineered compounds developed specifically for FGF, featuring improved dimensional stability, reduced warpage, good interlayer adhesion, and a wide processing window.
Why are polypropylenes critical in 3D printing?
Polyolefins tend to exhibit warpage and poor interlayer adhesion if they are not properly formulated for additive manufacturing.
In which industries is pellet-based 3D printing most widely used?
Materials research, functional prototyping, industrial product development, and large-format applications.
Accessibility Statement