3d-printed Composites Materials Markets – 2017: An Opportunity Analysis And Ten-year Forecast

Report # SMP-3D-COMP-1116
Published November 13, 2016

SmarTech Publishing is seeing growing interest and development activities around the use of composites – especially carbon- and glass-fiber reinforced thermoplastic materials within the 3D printing/additive manufacturing (3DP/AM) community

We believe that such developments are creating new revenue generation opportunities within 3DP/AM by expanding upon current labor-intensive composite materials manufacturing processes for the production of final parts in the transportation, medical and consumer goods industries.  3D-printed composites also add a new material to the ever-growing number of materials that can be printed by 3D printers.  And acceleration in the development of nanomaterial based composites, leveraging the materials’ advanced electrical, thermal and mechanical properties, is expected to further expand the range of 3D-printed composite applications over the next ten years.

This report determines the revenue potential from 3D-printed composites by examining both actual fabrication and notable R&D currently taking place at an enterprise and academic research level. It provides an analysis of upcoming developments based on how current applications for composites in manufacturing could be affected by the use of AM.

Ten-year volume and value forecasts of 3D-printed composite activity are provided for each primary adoption segment (aerospace, automotive, medical, service bureau and other industries) with breakouts by type of printers, material chemistries, material output and generated revenues.  In addition, this report provides an in-depth look at the product/market and manufacturing strategies of the leading firms and startups that are now pursuing the composite AM opportunity.  In addition, we include profiles of Stratasys, 3D Systems, EnvisionTEC, EOS, 3DXTech, Graphene Labs, Arvelo Labs, Cincinnati Incorporated, CRP Group, Advanc3D Materials, DWS, DeltaMed, Composite Manufacturing, among others.

Today the use of composites in additive manufacturing is limited.  However, the upcoming launch of several new technologies able to implement both continuous fiber composites and aligned chopped fiber composites indicates that the industry is about to enter a new phase of expansion.  SmarTech Publishing believes that AM is now viewed in the industry as way to streamline and automate manufacturing processes, without sacrificing the benefits offered by fiber based composites in terms of weight optimization and strength.

And, for the polymer 3D printing industry, the ability to 3D print composite materials parts represents a more direct path toward industrial end-use part and component production, including very large and geometrically complex parts for light weight airplane and car parts.

All of these developments, we believe, are positive for the future of 3D-printed composites.  This report will be essential reading for marketing, business development and manufacturing managers to discover where the opportunities are in this evolving market.

PAGE COUNT FOR THIS REPORT: 163

Chapter One: The Evolving Role of Composite Materials in 3D Printing
1.1 Key Drivers for 3D-printed Composites
1.2 Primary segments of application for composite materials and 3D printing
1.2.1 Competitive considerations for composite materials in manufacturing
1.2.2 Composite Materials in 3D Printing
1.2.3 Use of continuous fiber composites with thermoplastic extrusion technologies
1.2.4 Long fiber composites in pneumatic extrusion
1.2.5 Short Fiber Composites in Thermopolymer Filaments
1.2.6 Short Fiber Composites in Thermoplastic Powders
1.2.7 Nanocomposites with Photopolymers
1.2.8 Other Next-generation Composites for 3D Printing
1.3 Evolution of 3D Print Technologies for Composite Materials
1.3.1 Current State of the Art in 3D Printing Composites
1.3.2 Development of Production Grade 3D Printers for Use with Composites
1.3.3 Open Materials 3D Print technology Having Significant Impact on Future of Composite Printing
1.4 Notable Trends in Major Adopting Industries for 3D Printed Composites
1.4.1 Transportation Industry Targeting New, Higher Volume Composite Applications
1.4.2 Prosthetics and Orthotics (O&P) Industry Searching for Digital Solutions for Carbon Fiber
1.4.3 Sporting Industry May Use New Composites Manufacturing Processes for Product Differentiation
1.4.4 3D printed tools: the current sweet spot for 3D printed composites
1.4.5 When Will 3D Printed Composite Parts Become Common?
1.4.6 New Specialty Nanocomposite Photocurable Resins for the Dental Sector
1.5 Summary of Ten-year Forecasts for 3D Printed Composites
1.6 Key points from this chapter
Chapter Two: Analysis of Composite Print Technologies and Associated Markets 
2.1 Material Extrusion Technologies: Industrial Vs Low-Cost
2.1.1 Industrial FDM Use in composite manufacturing
2.1.2 3D Printed Lay-up Tooling for Composites
2.1.3 3D printed Sacrificial Tooling for Composites
2.1.4 Direct Additive Manufacturing of Continuous Fiber Composites
2.2 FFF use in low-cost composite manufacturing
2.2.1 Markforged’s Continuous Fiber Fabrication
2.2.2 Evolution of Chopped Fiber Composite Filaments
2.2.2.1 Nanocomposite Filaments
2.3 Composites in Vat Photopolymerization Technologies
2.3.1 Composite Photopolymerization 3D Printing Applications
2.3.2 Development of New Composite Materials for Photopolymerization
2.4 Polymer-based Composite Powder Bed Technologies and Materials
2.4.1 Development of Thermoplastic Powder Composite Materials
2.4.1.1 New Entries in SLS
2.4.2 How New Plastic Powder-bed Fusion Additive Technologies will Affect the Composite Industry
2.5 Lamination and Binder Jetting Technologies for Composites
2.6 Key points from this chapter
Chapter Three – Composite Materials Used in 3D Printing and Their Applications 
3.1 Carbon Fiber Opportunities
3.1.1 Applications for Carbon Fiber in Thermal Extrusion Technologies
3.1.2 Applications for Carbon Fiber in SLS
3.1.3 Supply Chain Considerations for Carbon Fiber
3.1.4 Future Outlook for Carbon Fiber Materials in 3D Printing
3.2 Glass fiber
3.2.1 Applications for Glass Fiber in Thermal Extrusion
3.2.2 Applications for Glass Fiber in SLS
3.2.3 Supply Chain Considerations for Glass Fiber
3.2.4 Future Outlook for Glass Fiber Composite Materials in 3D Printing
3.3 Other Fibers
3.3.1 Future Outlook for Other Fiber Composite Materials in 3D Printing
3.4 3D Printing with Nanocomposites
3.4.1 Considerations for Carbon NanoTubes (CNT’s) in 3D Printing
3.4.2 Considerations for Graphene and Carbon Nanofibers in 3D Printing
3.5 Key points from this chapter
Chapter Four: Key Players in Composite 3D Print Materials and Technologies: Strategic Profiles 
4.1 Key Players in Extrusion Materials and Technologies
4.1.1 Stratasys
4.1.2 colorFabb
4.1.3 3DXTech
4.1.4 Proto-pasta
4.1.5 TreeDFilaments
4.1.6. Black Magic 3D
4.1.7 Arevo Labs
4.1.8 Cincinnati Incorporated
4.2 Key players in powder bed fusion materials and technologies
4.2.1 EOS
4.2.2 CRP Group
4.2.3 Advanc3 Materials
4.2.4 3D Systems
4.2.5 Prodways
4.3 Key players in photopolymerization materials and technologies
4.3.1 EnvisionTEC
4.3.2 DWS
4.3.3 DeltaMed and Prodways Group
Chapter Five – Ten-Year Market Forecasts for Polymer 3D Printing 
5.1 Forecasting methodology
5.2 Key composite printing market metrics
5.3 Ten-Year Forecasts of 3D Printed Composite Products and Printers by Printing Technology
5.3.1 Material Extrusion Technology
5.3.2 Polymer Powder Bed Fusion (PBF) Technology
5.4 Ten-year forecasts of 3D printed composite material output by fiber material type
5.4.1 Output of 3D printed composite material sales in thermoplastic filaments and pellets
5.4.2 Output of 3D printed composite material in thermoplastic powder
5.5 Ten-year forecasts of 3D printed composite by vertical market
5.5.1 Composite thermoplastic filaments in major vertical markets
5.5.2 Composite thermoplastic powders in major vertical markets
About SmarTech Publishing
About the Analyst
Acronyms and Abbreviations Used In this Report 

List of Exhibits
Exhibit 1-1: Types of Fiber Reinforcements Considered in This Report
Exhibit 1-2: Composite Parts in Aerospace Manufacturing
Exhibit 1-3: Composite Parts in Automotive Manufacturing
Exhibit 1-4: Types of Composite Materials, Technologies and Applications
Exhibit 1-5: Benefits and Requirements of Using FDM for Lay Up Tooling
Exhibit 1-6: Benefits and Requirements of Using FDM for Sacrificial Tooling
Exhibit 1-7: Markforged Fiber and Polymer Materials for CFF
Exhibit 1-8: Leading Short Fiber Composite Filament Products for Thermal Extrusion
Exhibit 1-9: Leading Nano Composite Filament Products for Thermal Extrusion Systems
Exhibit 1-10: Timeline for introduction of composites in AM technologies
Exhibit 1-11: Applications for AM Composites in Motorsports and Automotive
Exhibit 1-12: Total Extrusion Composite Systems Install Base by Market 2014—2026
Exhibit 1-13a: AM of Continuous Fiber Composites – Adoption Cycle
Exhibit 1-13b: AM of Chopped Fiber Composites – Adoption Cycle
Exhibit 1-14: Growth of Composite Materials AM Market US$M (2014 -2026)
Exhibit 1-15a: and 1-15b Composite Materials in AM by Support Type US$M (2026)
Exhibit 2-1: AM of Composites: Processes and Materials
Exhibit 2-2: Industrial Composite AM Technologies Applications and Status
Exhibit 2-3: Available Composite Powder Materials for SLS
Exhibit 2-4a: SLCOM1 Preliminary Technical Specifications
Exhibit 2-4b: SLCOM1 Supported Polymer Matrix Materials
Exhibit 3-1: Applications/Opportunities for Carbon Fiber in AM
Exhibit 3-2: Total Carbon Fiber Composites Revenues in AM US$M 2014 - 2026 80
Exhibit 3-3: Carbon Fiber Composites in AM by Support Type - Market Growth 2014 - 2016
Exhibit 3-4: Carbon Fiber Composites Market Shares per Support Type (2026)
Exhibit 3-5: Applications/Opportunities for Glass Fiber in AM
Exhibit 3-6: Total Glass Fiber Composites Revenues in AM US$M 2014 - 2026
Exhibit 3-7: Glass Fiber Composites in AM by Support Type - Market Growth 2014 - 2016
Exhibit 3-8: Glass Fiber Composites Market Shares per Support Type (2026)
Exhibit 3-9: Other Fiber Applications/Opportunities in AM
Exhibit 3-10: Other Fiber Composite in AM Revenues US$M (2014 – 2026)
Exhibit 3-11: Nanomaterials Applications/Opportunities in AM
Exhibit 3-12: Carbon Nanotube Reinforced Composites in AM Revenues US$M 2014 – 2026
Exhibit 5-1 Total Extrusion Composite Systems Install Base by Market – 2014 - 2026
Exhibit 5-2: Total Polymer PBF Install Base by Market
Exhibit 5-3: Composite Extrusion Specialty Systems by Vendor - Total Units Sold 2014 - 2026
Exhibit 5-4: Powder Bed Fusion-based Composite Systems Sales and Install Base
Exhibit 5-5: Total Material Output by Reinforcement and Support Type 2014- 2026 (Kg)
Exhibit 5-6: Composite Material Output by Reinforcement and Support Type ($US Millions)
Exhibit 5-7: Total Sintered Composite Output (kilograms)
Exhibit 5-8: Total Sintered Composite Revenue ($US Millions)
Exhibit 5-9: Composite Filament and Pellet Output in Aerospace (Kg)
Exhibit 5-10: Composite Filament and Pellet Revenues in Aerospace (US$M)
Exhibit 5-11: Composite Filament and Pellet Output in Automotive (Kg)
Exhibit 5-12: Composite Filament and Pellet Revenues in Automotive (US$M)
Exhibit 5-13: Composite Filament Output in Medical (Kg)
Exhibit 5-14: Composite Filament Revenues in Medical (US$M)
Exhibit 5-15: Composite Filament and Pellet Output in Service Bureaus (Kg)
Exhibit 5-16: Composite Filament and Pellet Revenues in Service Bureaus (US$M)
Exhibit 5-17: Composite Filament and Pellet Output in Other Industries (Kg)
Exhibit 5-18: Composite Filament and Pellet Revenues in Other Industries (US$M)
Exhibit 5-19: Composite Powder Output in Aerospace (Kg)
Exhibit 5-20: Powder Revenues in Aerospace (US$M)
Exhibit 5-21: Composite Powder Output in Automotive (Kg)
Exhibit 5-22: Powder Revenues in Automotive (US$M)
Exhibit 5-23: Composite Powder Output in Medical (Kg)
Exhibit 5-24: Powder Revenues in Medical (US$M)
Exhibit 5-25: Composite Powder Output in Service Bureaus (Kg)
Exhibit 5-26: Powder Revenues in Service Bureaus (US$M)
Exhibit 5-27: Composite Powder Output in Other Industries (Kg)
Exhibit 5-28: Powder Revenues in Other Industries (US$M)


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