Printers

Integrating FGF Technology to Meet Industrial Needs

Large-format additive manufacturing (LFAM) by direct pellet extrusion, also called FGF (Fused Granular Fabrication), is a technology that until recently required not only a large investment, but was also not easy to make profitable and presented certain limitations in terms&helli

Integrating FGF Technology to Meet Industrial Needs
3Dnatives

Large-format additive manufacturing (LFAM) by direct pellet extrusion, also called FGF (Fused Granular Fabrication), is a technology that until recently required not only a large investment, but was also not easy to make profitable and presented certain limitations in terms of design and finishing. This production method consists of depositing molten plastic pellets on a printing bed layer by layer to gradually create the 3D object. To do this, the plastic pellets are fed to the extrusion head, which heats and presses them until a homogeneous molten plastic mass is obtained. In this sense, higher system performance results in higher build speed but a lower surface finish, and vice versa.

Discovery 3D Printers, the additive manufacturing division of CNC Bárcenas, specializes in the development of professional solutions based on FGF technology. According to its CEO, Francisco Bárcenas: “The growing and diverse market demand has driven us to offer increasingly customized solutions that are also more economical, so that more customers can access this technology”. In fact, the company, which is located in Valdepeñas (Ciudad Real, Spain), launched the Super Discovery 3D Printer in 2016, a machine with FGF additive manufacturing technology pioneer in Europe. The machine had an initial volume of 3.25m3 (1.3×2.5x1m), and its first customer was Navantia, as part of its “Shipyard 4.0” strategy.

FGF Technology

On the left, Francisco Bárcenas. On the right, the Super Discovery 3D Printer. (Photo Credits: Discovery 3D Printers)

Seeing the needs that existed in the market and the requests by some customers, in 2019 the company opted to develop models of higher production (up to 10kg per hour) and volume, reaching 11.25m3. Through this, it has managed to create the largest 3D printer in Europe to date. During this period, Francisco explains: “Several of our customers mentioned to us some important challenges related to the finishing of some final parts and tooling – such as molds – that were carried out by machining processes. We have been manufacturing CNC milling machines since 2009, and we considered merging both additive and subtractive manufacturing technologies”.