PEEK FGF pellet printing High-performance components made directly from pellets
Large-volume components made of PEEK or ULTEM without the detour via expensive filament.
In FGF pellet printing (Fused Granulate Fabrication), we process high-performance polymers directly from the granules.
The result: significantly lower material costs, larger build spaces and higher output than in classic FFF filament printing.
With our AIM3D ExAM 510, we are among the few suppliers worldwide to offer genuine PEEK pellet printing on an industrial scale. Combined with CNC post-processing for near-series dimensional accuracy.
Request a quote now, no obligation.
What is FGF 3D printing?
FGF stands for Fused Granulate Fabrication — the direct extrusion of plastic pellets in 3D printing. Instead of being made from a previously manufactured industrial filament, the component is produced directly from the raw material, just as it is used in the injection molding industry.
The crucial difference to the widely used FFF/FDM process: In FFF, the pellets are first processed into filament, wound onto a spool, and then melted again—an additional production step that incurs costs and processing energy. FGF completely skips this intermediate step.
Especially with high-performance polymers like PEEK, this difference is significant: filament PEEK costs many times more than pellets, and filament production is a bottleneck in the market in its own right.
Learn more about the properties and processing of PEEK in our PEEK 3D printing guide .
Both processes belong to the strand laying family. However, the raw material and therefore the overall economic viability differ fundamentally.
FFF/FDM vs. FGF:
The most important differences in detail
Kriterium | FFF / FDM (Filament) | FGF (Pelletdruck) |
|---|---|---|
Raw material form | Filament (plastic wire) | Granules (pellets, injection-molded goods) |
Material costs PEEK | High (500-700 €/kg) | Low (50-150 €/kg) |
Ejection / Printing speed | approx. 50–100 g/h | up to 500 g/h |
Installation space (typical) | smaller — usually < 300 mm^3 | larger — up to 510 × 410 × 410 mm |
Detailed resolution | Very fine (nozzles from 0.2 mm) | Coarser (nozzles from 0.4 mm) |
Material variety | Limited by filament availability | Virtually all injection-moldable compounds |
economy | Ideal for small parts, prototypes, small production runs | Ideal for large components & series production |
1. Direct use of materials
The pellets are the starting material for all PEEK semi-finished products. In FFF printing, filament is first produced from them. An energy- and machine-intensive step that significantly increases the price per kilogram. In FGF printing, we process the pellets directly. For large components, this translates into unit cost reductions of often 40–60%.
2. Larger components in one piece
FFF-PEEK printers are limited by their printing speeds. Pellet printers like the AIM3D ExAM 510 achieve very high printing speeds and can therefore economically produce large components. Large components that would necessarily have to be split and joined in FFF printing are printed in one piece.
3. Freedom of Compounds
Special compounds, such as PEEK ESD or PEEK MT, are often difficult or impossible to obtain as filament, but as pellets they are a standard product in the injection molding world. FGF opens the door to materials that are simply inaccessible with FFF printing.
Why FGF is a game-changer specifically for PEEK
You can find information about which PEEK variants and other high-performance polymers we process in our material overview .
Materials in FGF 3D printing at Malping
We focus on high-performance polymers that only demonstrate their full potential in large-volume components. Three material classes form the core of our FGF portfolio:
GF-PEEK
Stiffer behavior than pure PEEK with better dimensional stability. Preferred for structural components where Young's modulus and freedom from distortion are crucial, without introducing electrical conductivity.
CF-PEEK
Maximum specific stiffness and strength. For applications where weight reduction is required while maintaining full mechanical load-bearing capacity - typical in mechanical engineering, aerospace, and defense.
CF-PEEK (MT)
CF-PEEK for applications in the medical technology sector.
Request a free PEEK datasheet!
Compare different PEEK materials at a glance.
Not every component benefits from pellet printing.
The following rules of thumb will help you choose the right process:
When is FGF more advantageous than FFF/FDM?
FGF-Granulatdruck ist die richtige Wahl, wenn … | FFF-Filamentdruck bleibt die bessere Wahl, wenn … |
|---|---|
… the component has an edge length of >250 mm | … the component is delicate (wall thickness < 1.5 mm) |
… the material costs dominate the unit price | … highest detail resolution is required |
… a special compound (e.g. CF-PEEK MT) is required | … very small production runs with standard material |
… delivery time is critical (higher output rates) | …an existing FFF validation is running |
… you can join a large component monolithically today | … the geometry has many small undercuts |
You can find a complete procedural decision regarding CNC manufacturing here.
in our blog article "PEEK 3D printing vs. CNC manufacturing: When does 3D printing make sense?"
Typical applications for PEEK pellet printing
Mechanical and plant engineering
Large-volume functional components, structural supports, protective housings, and brackets for hot areas. FGF-PEEK demonstrates its strengths particularly where metal needs to be replaced by high-strength polymers.
Tools and fixtures
Clamping devices, grippers, hold-downs, gauges. Pellet printed tools withstand the stresses of real production and can be quickly adapted to manufacturing changes.
Semi-finished products & preforms
If a standard semi-finished product is too small, too expensive, or not available at all, we print the preform to near-net-shape specifications. We are also happy to handle the subsequent CNC machining step ourselves.
CNC machining for
near-series dimensional accuracy
FGF printing delivers near-net-shape geometry. We then produce functional surfaces, bores, threads, and tight tolerances using CNC technology—entirely in-house, without changing suppliers and without interface risks.
This combination of FGF printing and CNC post-processing is rare on the market. It is what makes pellet printing a serious method for near-series production components with tolerances that pure 3D printing cannot achieve.
More about our CNC machining of PEEK components.
What sets us apart from other providers
-
Industrial PEEK pellet printing: one of the few addresses worldwide with this combination of processes.
-
Three processes from a single source: FFF (filament), FGF (pellet) and CNC machining. We choose the most economical one for each component.
-
Compound freedom: virtually any injection-moldable pellets can be processed, not limited by filament availability.
-
In-depth materials expertise: Design advice on PEEK, ULTEM and other high-performance plastics based on practical experience, not data sheets.
-
Location Neuhausen auf den Fildern: short distances in the DACH region, personal support instead of anonymous online configurator.
Frequently asked questions about
FGF granule printing
How do mechanical properties of FGF-PEEK and FFF-PEEK differ?
With properly controlled FGF 3D printing processes, i.e., controlled crystallization and a temperature-controlled build chamber, the mechanical properties are comparable. Anisotropy (directional dependence) persists in both processes and must be considered in the design. For very large wall thicknesses, FGF can even offer slight advantages, as layer adhesion is better with thicker layers.
What tolerances are realistic?
In pure FGF printing, we expect tolerances of ±0.2 to ±0.5 mm, depending on component size and geometry. With subsequent CNC post-processing, we achieve tolerances of up to ±0.05 mm on functional surfaces - comparable to the pure semi-finished product CNC process.
Is FGF-PEEK biocompatible?
Biocompatibility depends on the pellet material. We process medically approved pellet upon request. For regulated applications, please contact us directly: material batch, process documentation, and cleaning must be agreed upon separately.
What is a reasonable minimum quantity?
FGF is cost-effective even for single components, provided they are sufficiently large. For smaller geometries, filament printing or other methods become more economical above a certain component size. We always provide unbiased advice in this regard.
Can you also process our special compound pellets?
Generally, yes. The prerequisites are processability on the ExAM 510 (viscosity, melting window, drying, shrinkage behavior) and a technical data sheet for the pellets. Please send us the data sheet, and we will assess its suitability promptly.
Which file formats do you accept?
STEP file format (.step / .stp) is preferred. Alternatively, STL is acceptable. For drawings only, without 3D data, we offer design services.
Your component in FGF pellet printing: talk to us!
Do you have a large component, a special compound, or a cost-sensitive application in PEEK, ULTEM, or another high-performance plastic? We will quickly assess whether FGF is the appropriate process and provide you with an honest evaluation, even if another process would be more economical.
Malping GmbH
Mörikestraße 29
(Production: Mörikestraße 30)
D-73765 Neuhausen auf den Fildern
Tel: +49-7158 9823230
Email: info@malping.de
If you already have a 3D model and would like to request a quote directly, please send us an email:info@malping.de
For general inquiries, please use our form: