FFF (fused filament fabrication) also known as FDM (fused deposition modeling) is an additive manufacturing technology, where an object is printed by extruding thermoplastic material layer by layer. Various materials are available for FFF. The best known representatives are Polylactic acid (PLA) and Acrylonitril Butadiene Styrene (ABS), but also other thermoplastics preferred with amorphous structure are available for printing. However, the industry demands for cost-effective materials possessing properties such as high chemical and corrosion resistance, higher impact strength and better temperature stability. In addition, the process stability and documented quality control are key issues to ensure an everyday deployment in industries.

PROFACTOR is interested in the development of methods for 3D-printing of polyolefins using the fused filament fabrication (FFF) technology. The goals are realized with analyses of commercially available filaments, development of tailored polyolefin compounds and adaptions to the printer, the printing-software and implementation of inline control systems.

  • Structure-property-relationship derived from the characterization of commercially available filaments enables the preparation of tailored materials with low shrinkage coefficients and good dimensional stabilities
  • Process-control system, based on near infrared sensors, heat-flow thermography, and optical size accuracy measurement technologies enables quality control of individual parts.
  • Hardware adaptions and process parameter optimization enables the production of parts using special materials


Within the project NextGen3D the implementation of commercially relevant polyolefins in FDM 3D-printing, from analysis of existing filament types via development of tailor-made polyolefin compounds to necessary adaptions on the printer is targeted. Most commercially available filament types consist ...+


Thomas Köpplmayr, Michael Mühlberger; Inkjet printing of polylactic acid on substrates prepared by fused deposition modeling and its potential for selective surface finishing, Journal of Applied Polymer Science 132 (2016) 43527, doi: 10.1002/app.43527

Thomas Köpplmayr, Lukas Häusler, Iris Bergmair, Michael Mühlberger; Nanoimprint lithography on curved surfaces prepared by fused deposition modelling, Surf. Topogr.: Metrol. Prop. 3 (2015) 024003

Mühlberger et al.; Digital Printing on 3D Printed Surfaces, Add+it 2016, Steyr, AT

Gerhard Traxler, Thomas Köpplmayr; Process Monitoring by Thermography during Fused Deposition Modeling, Polymer Processing Society Conference 2016

Hans-Jürgen Luger, Thomas Köpplmayr, Lukas Sobczak, Andreas Haider, Jürgen Miethlinger; Elongational rheology of glass-fiber and natural-fiber reinforced polypropylenes with a novel online rheometer, Polymer Processing Society Conference 2016

Köpplmayr, M. Mühlberger; Inkjet printing of polylactide on substrates prepared by Fused Deposition Modeling and its potential for selective surface finishing, Danube Vltava Sava Polymer Meeting

Köpplmayr, M. Mühlberger; Inkjet printing of polylactide on substrates prepared by Fused Deposition Modeling and its potential for selective surface finishing, Polymer Processing Society Conference 2015

Köpplmayr, L. Häusler, M. Mühlberger; Influence of stamp properties during imprinting on 3D printed surfaces, Micro and Nanoengineering 2015 MNE 2015

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Functional Surfaces and Nanostructures

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