Fused Granulate Fabrication

FGF

Pelletized ABS, extruded at high volume. Build envelope: 1200 x 1000 x 1000mm. When Industrial SLA isn't big enough, this is the machine.

Fused Granulate Fabrication (FGF) melts plastic pellets and extrudes them through a 4–6mm nozzle mounted on a large gantry system. The oversized nozzle deposits material fast but leaves a rough, layered surface that requires post-processing — sanding, priming, and painting. The trade-off is scale: FGF produces the largest parts in our catalog, up to 1200mm, in structural ABS.

When to choose FGF

Part too large for others

Oversized displays and props

Industrial patterns and tooling

Furniture prototypes

Cost over finish at scale

Strengths

  • + Largest volume (1200mm)
  • + Low material cost
  • + Structural ABS
  • + Architectural scale
  • + Paintable and finishable

Limitations

  • Coarsest layers
  • Roughest finish
  • Lowest accuracy
  • ABS only
  • Thickest min wall
01

Technology specs

Layer height0.5-2.0mm
Tolerances±1.0mm
Min wall thickness2.0mm
Max build size1200 x 1000 x 1000mm
Lead timeFrom 7 business days

Quick compare

Support scarringHigh
Level of detailLow
AccuracyLow
Price$$
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Design guidelines

Guidelines

Recommended parameters when designing parts for FGF.

Wall thickness
2.0mmMinimum recommended wall thickness
Support & overhangs
45°
Avoid overhangsSupport requirements and max overhang angle
Holes
Ø 5.0 mmMinimum hole diameter
Tolerance
±
±1.0mmExpected dimensional accuracy
Minimum features
3.0 mmSmallest printable feature
Clearance
2.0 mmRecommended clearance between parts

View full design guidelines →

03

Post-processing

Standard finishing included with every FGF order. Optional services available on request.

Included (standard)

Support removal— Supports cut with power tools and surfaces ground smooth.
Surface grinding— Coarse layer lines reduced with belt sanding. Critical surfaces machined flat.

Optional (quoted separately)

+
Assembly— Multi-piece builds bonded with structural adhesive. Seams filled and sanded.
+
Filling and fairing— Body filler applied to layer lines, sanded smooth, and primed.
+
Painting / priming— Full paint finishing for trade show pieces and display applications.
+
Coating— Protective coatings for UV resistance, chemical resistance, or food contact.

View full post-processing details →

04

Shipping & delivery

Every FGF order ships from our production facility in Brooklyn, NY. Lead time starts at From 7 business days. Enter your zip code to see exactly when parts will arrive at your door.

Local Pickup

Same day, free. Brooklyn facility, Mon\u2013Fri 10am\u20135:30pm ET.

Courier

Same day across all five boroughs and northern NJ.

Nationwide Shipping

UPS Ground, 2nd Day Air, and Next Day Air. Tracked and insured.

All shipping options →
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Compare FGF with others

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Ready to start production?

Upload your CAD file and get a quote in minutes — or talk to our engineers about your next production run.