CFF
Continuous Fibre Fabrication
Overview
CFF parts are built on a build plate surface. The part productivity depends upon the size of the object as it relates to the area of the build plate, the production time and finishing required.
Process Summary
- 1
Step 1
Printing
The printing stage involves two processes per layer. Firstly, a thermoplastic is extruded to form the infill and shells of the part. This provides the “matrix” material of the composite. Next, a separate print head deposits the continuous fiber which is ironed onto the matrix, fusing with the thermoplastic. This sequence is repeated layer by layer forming the fibers into the core of the part, with the thermoplastic acting as a shell. All support structures are deposited from the thermoplastic extruder.
- 2
Step 2
Support Removal
Manual Removal: Supports are breakaway, removed by hand or with tools; printed from the same or a secondary material. Soluble Support Removal: Available with dual-extruder systems using soluble support filament. Manual Cleaning Note: Support removal is straightforward; some internal support areas may require fine tools for cleanup.
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Step 3
Surface Finishing
Sanding / Polishing: Sanding can refine surface and prep for paint. Chemical Smoothing / Coating: Nylon-based parts do not respond well to vapor smoothing; surface treatments like epoxy coating or paint are used instead. Painting / Priming: Frequently done for visual or environmental protection; requires surface prep (e.g., sanding or priming.) Gloss / Matte Control: Surface is naturally matte; gloss finishes can be applied via coatings.
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Step 4
Curing / Heat Treatment
UV / Thermal Curing: Non-applicable; thermoplastics are fully cured during extrusion. Annealing / Stress Relief: Non-applicable.
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Step 5
Assembly and Functional Finishing
Gluing or Bonding: Industrial adhesives like epoxy or cyanoacrylate (superglue) can bond CFF parts to other components. Drilling / Tapping / CNC: Common practice; post-machining enhances precision or adds holes/features not achievable in print. Inserts / Fasteners: Threaded inserts (heat-set or press-fit) and mechanical fasteners are regularly used, especially in jigs and assemblies.
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Step 6
Special Treatments
Infiltration / Sealing: Non-applicable; CFF parts are solid and dense when printed correctly. Functional Coatings: Optional coatings for UV resistance, waterproofing, or chemical protection.
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Step 7
Productivity
CFF parts are built on a build plate surface. The part productivity depends upon the size of the object as it relates to the area of the build plate, the production time and finishing required. This information relates to the potential productivity of a single machine. All AM types can be arranged together to form print farms or smart factories that will increase productivity. These collections of multiple units can also provide opportunities for varying degrees of automation.
Technical Information
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