One Carbon Fiber, Multiple Base Materials, Endless Possibilities! eSUN Materials Academy Explainer

As 3D printing technology expands into professional applications, the limitations of single polymer materials in strength, dimensional stability, and heat resistance have become increasingly apparent. To meet the needs of real-world applications, carbon fiber reinforced composites have become one of the most representative high-performance materials in FDM 3D printing.

Why Are Carbon Fiber Reinforced Materials So “Strong”?

Carbon fiber (CF) has high specific strength, high modulus, and a low thermal expansion coefficient. When short carbon fibers are introduced into thermoplastic matrices (such as PA, PETG, or PEEK), they offer the following advantages:

Enhanced strength and stiffness: Carbon fiber has a much higher elastic modulus than common polymers, significantly increasing the bending modulus of composites. Under bending stress, the high-strength carbon fibers act as the main load-bearing elements, effectively preventing crack propagation and material failure.

Improved heat resistance and reduced warping: Carbon fibers exhibit high thermal conductivity and suppress polymer expansion, effectively reducing shrinkage and warping during printing. Adding CF increases the heat deflection temperature of the composite, especially for crystalline materials like PET and PA.

eSUN Carbon Fiber Series Material Selection Guide

When choosing 3D printing materials, we usually need to consider two core dimensions: printing adaptability and mechanical performance. Printing adaptability directly affects the surface quality, warping control, and print success rate of the finished part, while mechanical performance determines whether the material can be used in functional applications.

In terms of printing difficulty:

PLA-CF, PETG-CF, and ABS-CF are relatively easy to print, while nylon-based carbon fiber materials require higher printing skills.

In terms of performance characteristics:

PET-CF is the material with the highest strength, featuring excellent chemical resistance and a high heat deflection temperature after annealing, making it suitable for high-strength applications in high-temperature and high-humidity environments.

PA-CF offers outstanding strength, impact resistance, heat resistance, and chemical resistance. However, since nylon materials are hygroscopic, PA-CF is more suitable for high-temperature and high-durability environments, such as engine parts, fuel line components, connectors, gears, and bearings.

Although PA12+CF is not the strongest mechanically, it strikes a perfect balance between strength, toughness, and stability, making it an “all-around” performer. It also excels in impact resistance, lightweight design, and low moisture absorption—ideal for drones, aerospace, and sports equipment.

eSUN Carbon Fiber Series Material Classification and Introduction

Adding carbon fiber to different base materials results in varying degrees of performance improvement. According to their properties and usage scenarios, eSUN’s carbon fiber series materials are divided into entry-level and professional-level categories.

1. Entry-Level Carbon Fiber Reinforced 3D Printing Materials

PLA and PETG are common consumer-grade 3D printing materials. By adding a small amount of carbon fiber, their strength and rigidity can be improved, making them more suitable for printing tools, functional prototypes, and rigid structural parts.

Unlike professional-grade carbon fiber materials, PLA-CF and PETG-CF are easier to print and come in a widerrange of colors to meet diverse user needs.

Based on PETG’s inherent weather resistance, PETG-CF offers broader applicability, including outdoor and humid environments.

2. Professional-Grade Carbon Fiber Reinforced 3D Printing Materials

In addition to common PLA and PETG, eSUN has launched a series of carbon fiber reinforced 3D printing materials including PET-CF, ABS-CF, PA-CF, and PA12+CF.

ABS is a common engineering plastic. After adding carbon fiber, ABS-CF becomes stronger, more heat-resistant, and less prone to deformation. ABS-CF also features lightweight; for the same model, ABS-CF prints weigh 13% less than PLA-CF and 25% less than PET-CF.

Users struggling with printing need not worry – carbon fiber materials significantly reduce warping and improve dimensional accuracy.

PET is widely used in plastic bottles, automotive parts, etc., offering high mechanical performance, good heat resistance, and chemical resistance.

Adding carbon fiber significantly enhances its mechanical properties. Currently, PET-CF is the highest strength and rigidity material in eSUN’s carbon fiber composite series.

Additionally, based on PET substrate characteristics, PET-CF also features low moisture absorption.  Regarding printability, while there is a learning curve, it offers high printing precision.

In summary, PET-CF is suitable for harsh high-temperature and high-humidity environments, combining heat resistance, steam resistance, and structural stability. Specific applications include high-temperature pipelines and connectors, high-temperature and steam-resistant equipment, high-temperature fixtures, and automotive engine components.

*Friendly reminder: For better heat resistance, annealing the printed model is recommended.

PA-CF and PA12+CF are carbon fiber reinforced materials developed with nylon as the substrate, combining high strength and heat resistance, with excellent self-lubrication, fatigue resistance, and impact resistance.

Simultaneously, due to the carbon fiber addition, they both offer excellent dimensional stability and anti-warping properties, meeting application scenarios with high demands for structural part strength and durability, such as machinery and automotive industries.

Regarding differences: PA-CF uses general nylon as the substrate, offering higher rigidity and heat resistance; PA12+CF uses nylon 12 as the substrate, featuring lower water absorption, better dimensional stability, and stronger weather resistance.

PA-CF is more suitable for mechanical parts requiring high strength and heat resistance; PA12+CF performs better in lightweight and environmental adaptability.

eSUN Carbon Fiber Series Materials Printing Guidelines

 1.To ensure normal printing and optimal mechanical properties, drying before printing is recommended for all carbon fiber materials;

2. Carbon fiber materials are abrasive; using a hardened steel nozzle is recommended;

3. Carbon fiber materials are rigid and prone to breaking; therefore, avoid excessively long bowden tubes or sharp bends, and AMS usage is not recommended!

Carbon fiber reinforced 3D printing materials are not only important for functional prototypes but are gradually entering small to medium-batch end-part production. Their characteristics of “high strength, high rigidity, low thermal expansion” make them a crucial material system for the future industrialization of additive manufacturing.

For any needs or suggestions regarding carbon fiber composite 3D printing materials, please feel free to contact us.