Caracol unveils high-throughput xHF Extruder at JEC World 2025

Caracol, a global leader in large-format additive manufacturing (LFAM), launched the new high-throughput xHF Extruder, at JEC World 2025 in Paris, France. This new end-effector is now a configurable component of Caracol’s composite Heron AM LFAM platform, significantly boosting productivity with an extrusion rate of up to 75kg/h (165 lb/h). It enhances precision and introduces multi-material capabilities, allowing manufacturers to process two materials simultaneously through a double chamber and custom nozzles. This marks a major advancement in extra-large-scale 3D printing, catering to aerospace, marine, construction, and architecture industries.

“With this launch, we’re redefining what’s possible in large-scale additive manufacturing,” said Giovanni Avallone, Chief Innovation Officer and Co-founder of Caracol. “Working within the industry as both a service bureau and a technology provider, we recognize the gap in the market for this high-speed extrusion and advanced multi-material capabilities combination. This extruder will enable manufacturers to produce ultra-large, high-performance composite parts with greater efficiency and precision than ever before, opening up the benefits of AM to more industries without compromising on quality or material flexibility.”

The xHF (Extra Flow) Extruder is engineered and patented to maximize throughput, precision, and material flexibility. It features advanced plasticization and thermal control, minimizing component stress and increasing durability through dual-motor torque distribution. Its exceptional speed and precision enables high-volume production of large-scale parts. The four thermal control zones per extrusion chamber ensure superior material plasticization, while its capability to operate at temperatures up to 450°C (842°F) allows compatibility with high-performance composites. The extruder’s compact size and balanced center of gravity ensure agile machine setup, high movement speed, and maximized print volume.

By integrating the xHF extruder with the Heron AM platform, Caracol offers a unique combination of productivity and flexibility. Printing bi-material layers allows for producing high-performance composite parts more efficiently and cost-effectively. Manufacturers can combine a low-cost core material with a technical outer skin of high-performance thermoplastics, reducing macrostructure costs while maximizing each material’s advantages.

Designed specifically for extra-large applications, the xHF Extruder is ideal for manufacturing ultra-large components across multiple industries. Construction and architecture support the production of prefabricated structures, sustainable housing, and urban infrastructure. Within marine and aerospace sectors, it facilitates the creation of large-format molds, models, and functional components such as boat hulls. Industrial manufacturing enables the production of tooling, jigs, and custom-designed composite extra-large structures.

Caracol is showcasing the capabilities of the xHF Extruder at JEC World 2025, from March 4 to 6 in Paris, France. Visitors can witness Heron AM live-printing a lightweight and durable mold for composite tank lamination.