UPM Formi 3D20/19 pellets

The UPM Formi 3D 20/19 material by the Finnish company UPM Biocomposites debuted in 2018 at NORDIC 3D Expo with great success. UPM Biocomposites used their experience in the forest-based industry and sustainable innovation to create this biocomposite material, made from carefully selected wood-based cellulose fibers (20 %) sourced from PEFC-certified forests and native polylactide acid (PLA). UPM Formi 3D 20/19 was designed especially for Large Scale Additive Manufacturing (LSAM) and 3D printing and its unique thermomechanical behavior makes it efficient and easy to use in both of those manufacturing methods.

UPM Formi 3D 20/19 is available in the form of pellets safe and easy to print in open athmosphere. In general terms, granulate-based printing enables a much faster (up to 37 times) construction of large structures than filament-based methods. By combining advanced cellulose fibre and biopolymer technologies, the UPM Formi 3D 20/19 pellets allow for the manufacturing of high definition and light structures that are at the same time natural, sustainable and recyclable. The UPM Formi 3D 20/19 pellets are an extremely versatile solution that can be used in four ways:

1. For the manufacturing of moulds (concrete casting, vacuum infusion).
2. For large format 3D printing.
3. For desktop 3D printing.
4. For large or small scale filament production.

Image 1: A chair 3D printed with the UPM Formi 3D 20/19 pellets. Source: UPM Biocomposites.

While traditional mould manufacturing involves long lead times and a significant amount of waste generated by CNC milling, the UPM Formi 3D 20/19 pellets allow for a much simpler mould production where much less time and work is needed to manufacture a mould. This leads not only to faster lead times but also produces practically no waste and a significantly lighter mould, also compatible with plywood structures. The UPM Formi 3D 20/19 pellets give great results when printed with large diameter nozzles (2-8 mm) thanks to the dimensional stability and good melt strength of the material. 

Image 2: Mould 3D printed with the UPM Formi 3D 20/19 pellets. Source: UPM Biocomposites.

Although mainly oriented at LSAM, the UPM Formi 3D 20/19 pellets are also optimized to flow smoothly through smaller nozzles, and it has its proof in the unique thermomechanical behavior mentioned earlier. When in the molten stage, the UPM Formi 3D 20/19 pellets exhibit self-supporting properties, shear thinning melt flow, fast cooling and extremely low shrinkage. The cellulose fibers within the PLA base prevent the creation of internal stresses within the part and improve the sanding process and absorption of paints in post-processing.

Image 3: Parts made with the UPM Formi 3D 20/19 pellets can be post-processed just like wood. Source: UPM Biocomposites.

Furthermore, the printed part shows excellent first layer adhesion and the printing of round or other complex shapes is possible without a separate support material. The parts 3D printed with the UPM Formi 3D 20/19 pellets are characterized by a natural touch, a matte surface resembling wood, and a naturally yellowish color that is rich and remains bright since the cellulose fibers used do not contain lignin. The 3D printed parts can be post-processed just like wood by milling, sawing, sanding, staining, waxing, varnishing and painting.

Image 4: Mould manufacturing via granulate extrusion with the UPM Formi 3D 20/19 pellets. Source: UPM Biocomposites.

The ideal equipment for large scale format 3D printing with the UPM Formi 3D 20/19 pellets is the CEAD E25 extruder - a lightweight pellet extruder mountable on robotic arms, CNC machines or on the AM Flexbot by CEAD. The AM Flexbot is a flexible robot-based solution with a modular design that allows for customization according to manufacturing needs. Another option for large format pellet extrusion is the high-speed and high-flow Pulsar extruder by Dyze Design. As far as desktop format pellet extrusion, the UPM Formi 3D 20/19 pellets can also be used on the Mahor V4 pellet extruder - light, compact and compatible with many FDM 3D printers. Filament can be made with the UPM Formi 3D 20/19 pellets on a large scale but also in home conditions with the help of the Felfil ecosystem containing the EVO extruder and a spooler. The filament can be personalized with the help of PLA-based color masterbatches added during the extrusion process, resulting in a sustainable biocomposite filament with unique properties and in various color options.

E25 extruder - CEAD

AM Flexbot System - CEAD

Dyze Pulsar™ Pellet Extruder

Mahor V4 pellet extruder

The benefits offered by the UPM Formi 3D 20/19 pellets do not end here. In line with the sustainability and innovation philosophy practiced by UPM Biocomposites, the UPM Formi 3D 20/19 pellets are much more than an affordable LSAM solution. The cellulose within the pellets is a renewable resource with a scrap rate of production at almost 0 %, and it makes it possible for the pellets to be recycled (for example with the help of the Felfil plastic shredder) or burned for energy once the manufactured part is no longer needed.

Image 5: A kayak 3D printed with the UPM Formi 3D 20/19 pellets. Source: UPM Biocomposites.

The UPM Formi 3D 20/19 pellets are widely used in LSAM and their most common and recommended applications are the manufacturing of furniture, art and decor, moulds, for prototyping for architecture or the manufacturing of 3D printing filament. Using the UPM Formi 3D 20/19 pellets is a cost- and resource-efficient alternative for reducing the environmental impact of products and generating added value. Since the UPM Formi 3D 20/19 pellets are PEFC-certified, the end product can also obtain these certification, which can be used as marketing leverage and is a proof of the importance of ecological values for the brand.

The numerous possible ways of using the UPM Formi 3D 20/19 pellets means countless possibilities for sustainable and environmentally-conscious applications with the help of both LSAM as well as experimental extrusion with the help of compact pellet extruders or even desktop pellet extrusion solutions. The excellent thermomechanical behavior and properties of the UPM Formi 3D 20/19 pellets makes it an easy to work with material that guarantees reliable and unique prints that make a statement at the same time.