High-Speed Printing with Reinforced Filaments

The Hyper FFF® technology from Raise3D is a comprehensive high-speed 3D printing system that combines hardware, software, and specialized material improvements to increase productivity without compromising quality. In this context, the Hyper Core filament line was developed, a new generation of reinforced composite materials (with carbon or glass fibers) specifically designed for fast printing with Hyper FFF. Hyper Core filaments feature an optimized fiber distribution: fibers are concentrated in a thermally conductive internal core covered by a pure polymer outer layer. This design accelerates filament melting while keeping the exterior free of protruding fibers.

Image 1: Cross-section showing layers of Hypercore filament. Source: Raise3D

Advantages over traditional reinforced filaments

Printing at high speed with conventional composite filaments presents significant challenges. In standard reinforced filaments, the melt viscosity increases significantly, making extrusion difficult and limiting practical speed. Additionally, there is the “cold core” phenomenon, where the filament’s outer layer melts before its interior, leaving an unfused core and resulting in weak interlayer bonding. This reduces layer adhesion and mechanical strength while accelerating nozzle wear due to exposed abrasive fibers.

Hyper Core technology mitigates these issues through its innovative design: by concentrating fibers in the internal core and leaving the outer perimeter as pure polymer, it achieves high internal thermal conductivity. During high-speed extrusion, the fiber-rich core accelerates complete filament melting and retains residual heat, promoting more uniform interlayer bonding. As a result, printed parts gain Z-axis strength and improved surface quality. At the same time, without abrasive fibers on the surface, nozzle wear decreases and the object surface remains smooth. Overall, Hyper Core allows faster printing with better mechanical performance than traditional composites.

• Improved high-speed flow: optimized fiber distribution and the outer thermoplastic matrix reduce melt viscosity, enabling much higher print speeds without clogs.
• Superior interlayer adhesion: heat retained in the internal core facilitates material curing between layers, increasing Z-axis strength.
• Higher Z strength and rigidity: the aligned fiber content in the core reinforces the vertical structure. High elastic moduli have been measured (e.g., ~6.6 GPa in PPA GF25) and high tensile strength.
• Reduced nozzle wear: the pure outer layer protects the print head from direct contact with fibers, reducing wear.
• Warp-free parts: the special construction and material stability reduce warping compared to conventional reinforced filaments.
• Enhanced surface finish: the surface of printed objects is smooth and ready for post-processing (sanding, steam smoothing) without protruding fibers.

Image 2: Comparison table between Hypercore and traditional materials. Source: Raise3D

Available Hyper Core materials

The Hyper Core family includes several reinforced filaments aimed at different industrial applications. All are available on filament2print and formulated to be compatible with Hyper FFF®. Key examples include:

• Hyper Core PPA CF25: PPA (high-performance polymer) filament reinforced with 25% carbon fiber. Offers high rigidity and mechanical strength, ideal for parts that must withstand significant loads. Carbon fibers increase tensile strength and thermal stability, allowing high-temperature operation without material degradation. Suitable for demanding end-use applications such as structural machine components and lightweight molds.
• Hyper Core PPA GF25: PPA filament reinforced with 25% glass fiber. Offers rigidity and thermal resistance similar to CF25, but with higher impact resistance and lower warp tendency. High glass fiber content (6.6 GPa elastic modulus and ~189 °C thermal resistance) ensures dimensional stability in applications with vibrations or shocks. Recommended for structural parts in automotive, aerospace, and advanced manufacturing sectors.
• Hyper Core ABS CF15: ABS filament (engineering ABS terpolymer) reinforced with 15% carbon fiber. Combines ABS toughness and processability with fiber-added rigidity, producing durable and lightweight parts. Inherits impact resistance, chemical stability, and low moisture absorption of ABS, while the special fiber distribution improves Z-axis strength and prolongs nozzle life. Suitable for serial production and functional prototypes requiring a good balance of mechanical properties and controlled cost.

In general, all Hyper Core filaments are intended for high-performance industrial applications, where strong parts must be printed at high speeds without compromising quality.

Raise3D printers compatible with Hyper Core

To leverage Hyper Core filaments, hardware designed for high speeds and material resilience is required. Currently, compatible Raise3D models include:

• Raise3D Pro3 HS Series – High-speed dual extrusion printer (up to 300 mm/s) ready for Hyper FFF.
• Raise3D Pro3 Series with Hyper Speed Upgrade Kit – Standard Pro3 models enhanced with the upgrade kit enabling ultra-fast printing.
• Raise3D RMF500 – Large-format industrial dual-extruder printer, specifically designed for reinforced filaments (Hyper Core profile compatibility).

These systems feature reinforced extruders and advanced thermal control to handle the high temperatures and extrusion stresses of Hyper Core materials.

Real industrial applications

Hyper Core filaments have been adopted across industries where manufacturing speed and part robustness are critical. Key applications include:

Image 3: Hypercore materials are already used in automotive and other industries. Source: Raise3D

Automotive: Production of durable, lightweight functional components. Examples include intake manifolds, belt pulleys, and aerodynamic body parts (splitters, diffusers) made from reinforced plastic. Interior and exterior structural elements (seat frames, door mechanisms) and cooling system parts (fan turbines, fluid tanks) are also printed, leveraging Hyper Core’s thermal stability. These parts improve the vehicle’s strength-to-weight ratio and allow rapid functional design iterations.

Aerospace: Production of cabin and fuselage components requiring high thermal and mechanical resistance. Examples include knobs, luggage compartment latches, seat anchors, or lightweight antenna/sensor covers. HVAC components (ducts and grilles) and internal supports are also printed, enduring pressure and temperature variations. Fast production with Hyper Core enables rapid prototyping and small-batch custom parts.

Advanced manufacturing: Production of jigs, fixtures, and industrial tools, as well as functional prototypes. High strength and dimensional accuracy allow Hyper Core to produce custom tooling (guides, templates) and end-use parts for testing in sectors such as industrial machinery, electrical, and rugged devices.

These real-world applications demonstrate Hyper Core filaments’ capability to meet demanding requirements in automotive, aerospace, machinery, and high-end electronics sectors, offering high-speed printing without sacrificing performance.

Comparison with conventional composite filaments

Below is a summarized comparison table of key features of Hyper Core filaments versus conventional reinforced composite filaments:

This comparison illustrates that Hyper Core allows faster printing, stronger interlayer cohesion, higher rigidity, and improved surface finish, while requiring more specialized printers.

Video 1: High-speed printing with Hypercore ABS CF15 filament. Source: Raise3D