Xenia to unveil new high-performance filaments at Formnext 2024

Located in the town of Mussolente, just northwest of Venice, is Xenia, a company that has specialized in the production of thermoplastic polymers and composites for nearly 30 years. The Italian business has jumped onto our radar this past year as it has expanded its materials portfolio beyond the traditional injection molding market and into additive manufacturing, specifically large-format AM (LFAM). Excitingly, Xenia is preparing to showcase its 3D printing materials at the upcoming Formnext 2024 expo in Frankfurt, where visitors (us included) will be able to see a range of new FFF filaments firsthand.

While we patiently wait for Formnext 2024 to kick off, here’s a brief look at what to expect from Xenia and its new (and expanding) portfolio of AM polymers. 

Optimized for large-scale 3DP 

Xenia has leveraged its team’s years of experience engineering and manufacturing composite thermoplastics to bring a new range of 3D printing materials to the market, including carbon and glass fiber reinforced thermoplastics as well as ultralight materials for Fused Granulate Fabrication (FGF) 3D printing.

This range of materials has been optimized for large-scale applications. It offers a reliable combination of high stiffness, low density, dimensional stability, and low thermal expansion. These properties are conducive to various application types, including rapid prototyping and composite tooling.

3DF Materials

While Xenia offers a range of pelletized materials for 3D printing, its latest focus has been on introducing high-performance filaments for FFF 3D printing platforms. Notably, Xenia has launched a dedicated business unit, 3DF Materials, to represent these products. 

As 3DF Materials says: “Drawing on Xenia’s expertise in reinforced thermoplastic materials, we create a versatile array of filament-based solutions to meet the diverse needs of various applications.”

At Formnext 2024, Xenia and its 3DF Materials brand will present the company’s first four filament products: XELIGHT® 3DF, XECARB® SL 3DF, XECARB® 45 3DF, and XEGREEN® 23 3DF (we covered Xenia’s granulate portfolio in an in-depth piece you can read here).

XELIGHT 3DF

This filament is based on an ultra-light PEBA thermoplastic elastomer and combines several beneficial properties, like good flexibility, impact resistance and light weight. According to Xenia, its XELIGHT 3DF filament has been optimized to improve PEBA’s inherent properties, including a 20% reduction in weight compared to standard PEBA grades, which translates to a density of 0.87 g/cm³. XELIGHT 3DF also offers good energy return and is ideal for applications where flexibility and weight reduction are key.

XECARB SL 3DF

This filament is a high-performance composite thermoplastic made up of bio-based PA11 with 15% carbon fiber reinforcement. The composite, engineered using Xenia’s SuperLight technology, is characterized by its excellent strength-to-weight ratio, chemical resistance, low moisture absorption and high impact strength. SuperLight technology, as the company explains, results in a structural filament that is optimized for weight reduction and strength. Compared to standard PA11 carbon fiber, XECARB SL 3DF reportedly demonstrates a 15% increase in tensile modulus and up to 10% weight reduction. Notably, the PA11 used as the base for the material is sourced from renewable castor oil.

XECARB 45 3DF

Also in the XECARB family is XECARB 45 3DP, a high-performance filament made up of structurally modified PVDF and 10% carbon fiber reinforcement. PVDF is a non-reactive thermoplastic known for its excellent chemical resistance (to acids, bases and solvents), durability, impact strength, tensile strength, low permeability, UV and flame resistance and good dieletric properties. This combination of material properties has made PVDF particularly viable for electronic applications and outdoor uses. Xenia’s structurally modified XECARB 45 3DF filament is notable for its enhanced conductivity (it is twice as conductive as standard PVDF grades).

XEGREEN 23 3DF

The fourth 3D printing filament that Xenia is bringing to Formnext 2024 is XEGREEN 23 3DF, a thermoplastic composite made entirely from recycled materials. The filament is composed of 20% recycled carbon fiber in a matrix of “rigorously selected” recycled PETG. In addition to being more sustainably sourced than filaments based on virgin plastics and fibers, XEGREEN 23 3DF brings a number of beneficial properties to the table, including high strength-to-weight ratio, chemical resistance, impact resistance, ductility and low thermal expansion. Ideal for applications where durability is a requisite, the recycled filament offers functional properties with the benefits of being recycled.

“Our aim with the 3DF Materials division is to meet the technical demands of the most challenging projects,” the company says. “Xenia’s range of filaments spans from ultra-lightweight materials with high impact resistance to superlight structural materials featuring a density of 0.99 g/cm³, offering a unique blend of lightness and strength.”

Ultimately, these new high-performance filaments will enable industrial and professional FFF users to both expand their applications and enhance the quality and properties of existing applications. All four filaments and more of Xenia’s 3D printing offering will be exhibited from November 19-22 at Booth G48, Hall 12.1 at Frankfurt am Main. Don’t miss it!