Xenia launches thermoplastic composite pellet range for large-scale additive manufacturing
Materials developer releases eight reinforced compounds targeting jigs, molds, and structural components produced on pellet extrusion systems
Xenia, an Italian developer of carbon and glass fiber-reinforced thermoplastic composites, has released a new line of pellet-based materials engineered for large-scale additive manufacturing (LSAM) tooling applications.
The portfolio addresses thermal stability and dimensional accuracy requirements in the production of jigs, lamination masters, thermoforming molds, and master models on pellet extrusion 3D printing systems.
The materials are formulated to perform across service temperatures from ambient conditions up to 260°C, with low coefficients of thermal expansion (CTE), high stiffness, and structural stability intended to minimize distortion during printing and autoclave processing.
Eight compounds across polymer matrices
The portfolio spans eight material grades. PETG, available in carbon and glass fiber-reinforced versions, targets large-format functional parts requiring chemical durability and UV resistance. ABS-CF covers prototyping, trimming jigs, and general industrial tooling. PC-CF offers thermal resistance to approximately 140°C with autoclave compatibility. PC-HT-CF builds on that with higher toughness and improved printability for automotive and aerospace tooling.
At the higher end of the performance range, PEI-CF targets high-temperature tooling and structural components in aerospace and defense. PESU-CF offers flame retardancy and chemical resistance for precision industrial environments. PEEK-CF provides a lightweight alternative to metal for high-end applications under aggressive conditions. PEKK-CF combines thermal stability and mechanical strength for continuous high-temperature use, with tunable crystallinity achievable through controlled post-cure treatment and easier processing relative to PEEK.
The range is positioned for sectors including aerospace, automotive, motorsport, defense, marine, construction, energy, and transport.
Addressing large-scale production consistency
“We developed this specific range of thermoplastic compounds to address the key challenges of LSAM tooling, from thermal stability to dimensional control,” said Alfio Agostini, Account Manager of Xenia’s 3DP Materials Division.
“Through a combination of advanced material engineering and process optimization, we enable manufacturers to produce large-scale tools more efficiently and with greater consistency.”
Xenia will exhibit the portfolio at FIP – France Innovation Plasturgie 2026 in Lyon, France, from June 2 to 5.
