Carbon fiber nylon filament is an exciting material for 3D printing that combines the strength and stiffness of carbon fiber with the flexibility and durability of nylon. This composite filament offers superior mechanical properties that make it ideal for printing strong, stiff parts and functional prototypes.
What is Carbon Fiber Nylon Filament?
Carbon fiber nylon is a composite material made by blending nylon plastic with tiny carbon fibers. The carbon fibers act as a reinforcement that enhances the strength, stiffness, and dimensional stability of the nylon.
Carbon fiber filament typically contains around 15-20% carbon fiber by weight. The carbon fibers are very small, usually 5-9 microns in diameter, and several millimeters long. This allows them to be evenly dispersed throughout the nylon during extrusion into filament.
The resulting carbon fiber nylon material combines the best attributes of its components. The nylon provides a tough, durable, and slightly flexible plastic matrix. The carbon fibers bolster the strength, rigidity, and thermal stability.
Key Features and Benefits
Here are some of the key benefits that carbon fiber nylon offers for 3D printing:
- Exceptional strength – Carbon fiber reinforcement boosts tensile strength and makes printed parts much stronger than pure nylon. Strength is even higher than popular materials like ABS.
- Increased stiffness – The carbon fibers limit flexing, resulting in stiffer and more dimensionally stable 3D printed parts. Rigidity is improved by 200-300% compared to nylon.
- Low creep deformation – Parts maintain their shape better under load over time, with less tendency to slowly deform. This makes carbon fiber nylon well-suited for load-bearing components.
- Abrasion and wear resistance – The material is highly resistant to wear in moving parts. This is ideal for applications like gears, sliders, bearings, and robot joints.
- Lightweight – Despite its strength, carbon fiber nylon remains relatively lightweight. Printed parts have a density similar to pure nylon.
- Improved thermal properties – The carbon fiber increases heat deflection temperature. Printed parts can better retain shape and strength in hot environments up to 80-100°C.
- Easy printing – Carbon fiber nylon filament prints easily on most standard FDM/FFF desktop 3D printers with a heated print bed. Minimal warping occurs.
Drawbacks to Consider
Carbon fiber nylon also has some disadvantages to keep in mind:
- Abrasive to nozzles – The carbon fibers tend to slowly erode brass print nozzles over time. Abrasion-resistant nozzles are recommended for longer nozzle life.
- Prone to “hairy” prints – The carbon fibers on the surface can create a fuzzy texture on prints. Proper cooling and dialed-in settings helps minimize this.
- Lower impact strength – Impact resistance is reduced versus pure nylon. Parts are more prone to shattering from sudden impacts.
- Conductive – The carbon makes the material slightly conductive, which may limit uses in electronics. Insulating layers can overcome this.
- More expensive – Carbon fiber nylon costs around 2-3 times more than pure nylon filament. The added performance comes at a premium price.
Ideal Uses for Carbon Fiber Nylon
The exceptional mechanical properties make carbon fiber nylon filament ideal for:
- Functional prototypes – Provides extra strength for load-bearing prototypes, while still being easy to print.
- Production end-use parts – Durable enough for final parts that need strength, stiffness, heat resistance, and low creep.
- Automotive components – Great for interior and under-the-hood automotive parts that experience high heat environments.
- Aerospace applications – Meets strength and heat resistance needs for lightweight aircraft components.
- Robotics parts – Excellent for robotic arm links, grippers, gears that undergo wear and loading forces.
- Mechanical systems – Suitable for pulleys, bushings, cams, bearings and other mechanical parts that need rigidity.
- Outdoor products – The abrasion resistance suits applications like outdoor equipment that experiences wear.
How to Print With Carbon Fiber Nylon
Printing with carbon fiber nylon filament takes a bit more finesse than typical plastics. Here are some tips for success:
- Print Bed Adhesion – Use high bed temps up to 80-90°C to prevent warping. Adhesion aids like glue, tape, or PEI can also help the first layer stick.
- Nozzle Temperature – Print hot, around 250-270°C to allow for good layer adhesion. Some sources recommend even higher around 285°C.
- Cooling – Slow cooling can reduce layer adhesion and cause “hairy” fuzzy prints. Use active cooling fans at 100% speed.
- Lower Speeds – Keep print speed reduced, around 40-60mm/s, to prevent jamming and allow filament to bond properly.
- Abrasion-Resistant Nozzles – Use hardened or ruby nozzles to minimize nozzle wear from the carbon fiber.
- Enclosed Printers – Enclosures help prevent small air currents from disrupting tricky overhangs and bridges.
- Proper Retraction – Dial in retraction settings to prevent oozing. Start with 4-6mm retraction at 25-40mm/sec speeds.
- No Heated Bed – Some sources indicate heating the bed above 100°C can outgas the nylon, degrading print quality.
Top Brands of Carbon Fiber Nylon Filament
Several respected filament manufacturers have developed quality carbon fiber nylon materials:
- Markforged NylonX – One of the first carbon fiber nylon composites at a 12% fiber content. Designed for Markforged’s industrial composite printers.
- 3DXTech CarbonX – A popular option with 15% fiber that prints well on desktop FDM machines. Available in different fiber lengths.
- Polymaker Polymax PLA + Carbon Fiber – A unique blend of 10% carbon fiber in a PLA-nylon alloy copolymer.
- Gizmo Dorks Nylon + Carbon Fiber – Budget-friendly alternative with 15% carbon fiber reinforcement.
- Proto-pasta Composite Carbon Fiber PLA – Blends fine milled carbon fibers into tough PLA plastic for strength.
- ColorFabb nGen – Quality nylon filament with 15% chopped carbon fiber strands evenly dispersed.
The Strength Future of Carbon Fiber Nylon
Carbon fiber reinforced nylon filament brings aerospace-grade composites to desktop 3D printing. As the technology continues improving, carbon fiber nylon will become easier to print and more widespread.
Material suppliers will continue enhancing the strength, layer adhesion, and printability of their composite filaments. 3D printer manufacturers may also develop systems better optimized for tricky materials like carbon fiber nylon.
The result will be even stronger and higher performance printed parts. Carbon fiber nylon makes it possible for designers to 3D print durable components previously unachievable with typical plastics. It ushers in new possibilities across industries like aerospace, automotive, manufacturing, and healthcare.
