Meet the FX10: The First Industrial Metal and Composite 3D Printer

In the fall of 2023, Markforged launched the FX10, a next-generation composite printer with Metal Fused Filament Fabrication (FFF) capability. This makes the FX10 the first industrial printer able to produce both composite and metal parts. Designed from the ground up for this dual capability, the FX10 offers exciting possibilities for users. In this blog post, we'll explore its development and implications for potential users.

Process Comparison: Composite and Metal

Before discussing the FX10, it's essential to understand the two processes it combines for printing metal and composites: Fused Filament Fabrication (FFF) and Continuous Fiber Reinforcement (CFR).

Markforged's composite printers employ FFF, a standard 3D printing method that extrudes heated thermoplastic filament in layers to form parts. CFR enhances this by using a second extrusion system to add long-strand continuous fibers, replacing the typical FFF infill. This results in parts that are up to 10 times stronger than standard FFF materials, making them suitable replacements for aluminum in various applications. Markforged developed a process known as Metal FFF to print near-net-shaped metal parts with no metal powder exposure. Metal FFF is a three-step process, as detailed below.

• Print:A specialized FFF printer uses polymerized metal powder to create parts. The polymer melts and extrudes with the metal powder, and the parts are printed with same-material supports separated by Ceramic Release material. The "Green Parts" are scaled up by ~20% to account for shrinkage.
• Debind:Green Parts are immersed in a solvent to dissolve the polymer, resulting in "Brown Parts."
• Sinter: Brown Parts are sintered in a furnace, becoming fully metal parts. They shrink about 20% during this process and have near-net shape accuracy with open cell infill.

Bridging the Gap

To build a metal and composite FFF printer, Markforged engineers faced a challenge due to the incompatibility of polymer and early metal filaments. Polymer filaments require sealed pathways to limit moisture, while early metal filaments were too brittle and needed open tubing, making dual-capable machines difficult to develop.

To address this, Markforged created Metal FFF filaments with an optimized polymer binder for 3D printing, leading to “Flexible” filaments that were easier to handle, reduced nozzle jams, and could be routed through feed tubes without breaking. The first flexible filament, Copper, was released in 2020, followed by updated versions of popular steels (17-4PH v2, H13 v2, D2 v2). A 316L stainless steel version will be available next year. While flexible filaments solved the fundamental problem of building a dual system, Markforged engineers still needed to find a way to build a reliable system designed to print to very different media. To do that, they built the most modular machine we’ve ever created.

How it Works

FX10 is designed with the understanding that metal and composite filaments require entirely different hardware to transfer material from spool to part. To achieve this, Markforged has made the crucial components of the print engine interchangeable, as listed below.

• Print Head: The machine has two dedicated print heads—one for composite materials with a plastic and fiber nozzle, and one for metal with nozzles for metal filament and ceramic release. Both heads can be swapped with two screws.
• Material Routing Block: Located at the back, this block connects four feed tubes. The composite block routes to a single outlet, while the metal block has two outlets for metal filament and ceramic. It can be swapped with a single screw.
• Material Tubes: Dedicated tubes prevent cross-contamination between metal and composite filaments.

In addition to the three main parts of the print engine, you also need to replace some other parts, including the print sheet, purge bin, and spool holder. The entire changeover takes about 15 minutes. After this, the machine will calibrate itself, which takes around an hour.

With the FX10, you can switch between metal and composite printing in less than two hours. However, metal printed parts still need to be washed and sintered using the same additional machines that Markforged provides.

The End Product

The FX10 is offered in two variants: Composite and Metal + Composite. The composite variant includes the printer, while the Metal + Composite variant comes with the printer (in composite format), the FX10 Metal Kit, the Wash-1, and a Markforged sintering furnace. A user who buys the composite-only FX10 can gain metal capabilities by acquiring the Metal Kit, Wash-1, and a sintering furnace. A customer with pre-existing Markforged Metal FFF capabilities (through the Metal X) can obtain an FX10 with a Metal Kit to enhance their metal capabilities.

The FX10 will be compatible with all of Markforged's current flexible metal filaments: 17-4PH v2, Copper, H13 v2, and D2 v2. Along with the legacy materials from Markforged, a new filament will be launched exclusively for the FX10: 316L stainless steel. This stainless steel, known for its exceptional corrosion resistance, is advantageous in industries such as food and beverage, maritime, and others.

FX10 Metal and Composite Applications

The FX10 is the inaugural FFF printer that can handle both composite and metal printing, making it the first machine to address a complete spectrum of manufacturing needs. The capabilities of industrial metal and composite 3D printing are highly synergistic, enhancing each other's advantages.

Composite Excels At

• Large Parts:Metal FFF has inherent part size constraints due to sintering. For parts larger than 15 cm, composite printing is typically a better option.
• Designed Compliance:Composite and plastic parts can be designed to yield or bend under load, making them ideal for various fixtures.
• Non-Marring Surfaces: Composites do not mar surfaces, making them ideal for handling delicate materials.
• Low Cost and Fast:Compared to Metal FFF's three-step process, composite printing can produce parts more quickly and at a lower cost than metal.
• Tighter Tolerances:While metal can be post-machined, composites offer much tighter tolerances when printed than metal.

Metal Excels At

• Strength and Hardness: Composites are strong; however, stainless and tool steels provide strength that only metals can achieve. Furthermore, metals are significantly harder than composites as they are printed, and some can undergo further hardening.
• Heat Resistance:For parts operating in environments above 200 ºC, metal is the only option.
• Abrasion Resistance:Along with being hard (and hardenable), metal offers far superior abrasion resistance for parts subject to repeated.
• Machinability:Metal parts can be machined to tight tolerances or mirror surface finishes.
• Heat and Electrical Conductivity:Copper provides unique heat and electrical conductivity for parts with specific requirements.

Composites solve many problems, but sometimes you just need metal.

The complementary strengths of composites and metals manifest in three key areas: shared applications, unique applications, and hybrid applications. In certain scenarios, similar to arm tooling, composites and metals excel for different reasons. Composite End-of-Arm Tooling (EOAT) can include non-marring grippers and vacuum tools, while metal EOATs are typically used as production grippers in high-volume applications. Having access to both technologies broadens the range of applications to accommodate a greater variety of parts.

Different materials serve specific engineering applications effectively. For composites, factory aids like brackets and mounts benefit from the low cost and speed of composite printing. In contrast, high-temperature tools, such as brazing fixtures, must be made from metal to withstand the heat. Hybrid applications combine the advantages of both metals and composites, creating optimized tools like end-of-arm tooling with composite bodies and metal wear pads. This combination allows for customized solutions that leverage the strengths of each material for unique manufacturing needs.

In Conclusion

The FX10 is a top-tier machine designed for composites, and with metal capabilities, it's now the first Fused Filament Fabrication (FFF) printer that can produce both metal and composite parts. Markforged is considered the most versatile tool for factories. When you're considering your next purchase in 3D printing, the FX10 stands out as a top choice.

If you're looking for a powerful, dual-capability printer that can elevate your production capabilities, be sure to check out Chemtron, Singapore’s leading distributor of Markforged printers. Elevate your projects to new heights with the FX10!