Zed
Zed is a technical writer with over 30 years of experience in the 3D printing and manufacturing industries. Having worked internationally since 1992, Zed focuses on the practical applications of cutting-edge technologies, particularly in the realm of industrial 3D printing. Passionate about material efficiency and innovative design, Zed brings a hands-on approach to exploring the evolving landscape of modern manufacturing.
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In the ever-evolving world of 3D printing, Fused Deposition Modeling (FDM) has made significant strides over the years. Traditionally, FDM has been limited to relatively simple, planar builds that are restricted by the physical constraints of three-axis motion. However, as hardware innovations push the boundaries of what’s possible, the industry is now standing on the precipice of a revolutionary leap forward: 5-axis FDM printing.
This emerging technology—though still in its early stages—is set to completely transform how we design and manufacture complex objects. From lightweight aerospace parts to customized medical devices, the introduction of multi-axis printing is not just a small enhancement—it’s the gateway to a new era of material efficiency, faster production times, and more intricate, support-free geometries.
Let’s take a closer look at the real-world implications of this breakthrough, examining how it will impact material savings, print speeds, and the types of geometries that were once unimaginable within the realm of FDM printing.
The End of Speed Limitations: Hardware vs. Materials
For years, the speed limitations of 3D printers have been a topic of debate. Manufacturers have continually pushed the hardware capabilities of FDM printers to new heights, but they have met an obstacle: the materials themselves. Today, current high-speed filaments—such as PLA, PETG, and TPU—have reached their theoretical speed limits. Despite hardware advancements, materials like these simply cannot handle faster print speeds. Speed and quality have reached a plateau, with the material composition and thermal characteristics becoming the limiting factor, not the hardware’s performance.
This phenomenon is clear: the hardware—especially delta-style 3D printers—has outpaced the capabilities of available filaments. While delta printers are designed for speed and agility, the high-speed filaments that can match those speeds simply don’t exist in the quantities or quality required for mainstream FDM use. Until newer high-speed materials are developed, this is the ceiling for current 3D printing technology. Moreover, there is no public demand for speeds beyond those already achievable with the types of materials that can currently handle the speeds of modern 3D printers. Innovations need to focus on other aspects of the printing process, such as material properties, precision, and complexity.
As we see hardware advancing toward new speed thresholds, it’s clear: the future of 3D printing isn’t just about faster speeds—it’s about maximizing the efficiency and complexity of the materials we can use.
The Game-Changer: 5-Axis Printing
Enter 5-axis FDM printing. At its core, 5-axis printing extends the traditional three-axis system (X, Y, Z) with two additional rotational axes—allowing the print head to move not just in straight lines, but also around curves and angles. Anycubic’s foldable portable 5-axis printer concept has already shown the possibilities of this technology, collapsing into a briefcase-sized machine that can print full-size objects, all while utilizing this new range of motion.
But the real value of 5-axis printing goes beyond space efficiency. The ability to print at non-planar angles—printing across surfaces that would normally be impossible—opens the door to new material-saving opportunities. Typically, support structures are needed when printing objects with overhangs, resulting in material waste and the time-consuming process of removing supports post-print. With 5-axis printing, support structures become obsolete. The print head can be rotated and tilted in such a way that it prints directly onto overhangs, with well-designed prints, potentially eliminating or greatly reducing the need for support material altogether. This alone will dramatically reduce material waste and enhance the quality of the final printed parts.
For industries that use high-performance industrial filaments—such as PEEK, Ultem, and PEKK—these savings are significant. For example, a spool of PEEK might cost around $400 per kilogram—a significant investment, especially for small businesses or research labs working on prototypes or custom parts. By utilizing multi-axis printing to avoid the need for excessive support structures, users can significantly reduce the overall material used. When every gram of filament counts, the ability to minimize waste during the printing process translates directly into cost savings.
In industries where high-performance thermoplastics are a requirement—like in aerospace, where materials need to withstand extreme temperatures and mechanical stress—the savings can quickly add up. Using off-axis printing to create parts with organic curves and complex structures allows users to make the most out of every spool of expensive filament. By removing the need for bulky support structures and enabling the creation of lightweight, optimized designs, manufacturers can maximize the value of every spool of these expensive materials.
Moreover, the ability to print in complex geometries without relying on support structures allows for lighter, stronger parts that are optimized for their intended function. This is particularly important in industries like aerospace, where every gram counts, and high-strength-to-weight ratios are critical. The combination of off-axis printing and optimized part design opens up new possibilities for creating parts that are both stronger and lighter—ultimately reducing both material costs and production times.
Cost Implications: From Hobbyist to Industry
The potential for material savings with 5-axis printing isn’t just theoretical—it can be applied to both the hobbyist and industrial sectors. For hobbyists using standard materials like PLA and PETG, the ability to print without supports means that the cost per part drops significantly. Instead of using large amounts of filament for support material that will be discarded, hobbyists can create cleaner, more efficient prints with less waste.
However, the real impact is felt when industrial materials are used. As previously mentioned, exotic materials like PEEK and Ultem can cost up to $400 per kilogram. In traditional FDM printing, a significant portion of this material is often lost to support structures. By avoiding supports and optimizing print orientation with 5-axis motion, companies can save hundreds or even thousands of dollars per project, depending on the complexity and size of the parts being printed.
This isn’t just about reducing waste; it’s about unlocking new possibilities for design and innovation. Complex geometries, once reserved for high-end manufacturing or impossible to produce with traditional FDM, can now be created with ease. This means that innovative designs—whether they are customized parts, unique prototypes, or functional components for high-performance industries—can be produced faster and at a lower cost than ever before.
A Broader Look at Materials and Their Role in 5-Axis Printing
The materials that prosumers and industry professionals will be able to use with 5-axis printing are not just limited to high-performance thermoplastics like PEEK, Ultem, and PEKK. Carbon fiber composites, such as PA12-CF (Nylon 12 with Carbon Fiber), are also becoming increasingly popular in the prosumer market. These materials offer excellent strength-to-weight ratios, making them ideal for engineering prototypes and automotive parts.
While these composites can cost anywhere between $100–$250 per kilogram, the ability to print more efficiently by reducing waste and avoiding the need for excess support allows users to make the most of these specialized materials. The abrasive nature of carbon fiber filaments, which typically require hardened nozzles, can also be mitigated through optimized printing, extending the life of printer components while delivering high-quality parts.
Implications for the Future: A New Standard for 3D Printing
The convergence of 5-axis FDM printing, material efficiency, and high-performance filaments suggests that the next generation of 3D printers will redefine not only what is possible but also what is practical in both the consumer and industrial markets. For prosumers, the ability to print complex geometries without relying on supports, all while saving money on high-cost materials, opens up new doors for innovation, customization, and optimization. For industry professionals, the efficiency of 5-axis printing could lead to faster prototyping, lower material costs, and quicker product iteration.
While current speeds and hardware limitations may have reached their peak with existing materials, 5-axis technology represents a shift toward improving design complexity and material usage, rather than pushing for ever-increasing speeds. The future of 3D printing lies not in faster print times, but in how intelligently and efficiently we can use the materials at our disposal. By harnessing the power of multi-axis printing, we are stepping into an era where design freedom is no longer constrained by material waste, printing limitations, or the need for support structures.
In conclusion, 5-axis FDM printing is not just a technological upgrade; it’s a paradigm shift that will reshape the way we think about manufacturing and material consumption. By utilizing this technology, we will see smarter, more sustainable production, and with it, a future where the cost of materials no longer limits innovation, but instead fuels it.
All opinions expressed in this article are the author’s own and are not endorsed by or affiliated with Anycubic.
