Continuous Carbon Fibre 3D Printing — Metal-Replacement Strength
Forge Labs runs a fleet of Markforged systems printing continuous carbon fibre, fibreglass and Kevlar reinforcement through carbon-filled nylon — producing structural parts that genuinely replace machined aluminium at a fraction of the lead time and cost.
Typical projects start from $500+ · Engineering & business enquiries welcome · Upload CAD, STEP & STL files for review
Manufactured in
Sydney, Australia · Quality-checked on every job
Why Forge Labs
Why engineers choose CCF over machined aluminium
Markforged continuous reinforcement gives you metal-grade structural performance with additive economics.
Stronger Than Aluminium
Continuous carbon fibre reinforced parts achieve stiffness comparable to 6061-T6 aluminium at a fraction of the weight.
Metal-Replacement Capable
Brackets, fixtures and load-bearing parts previously machined from aluminium can now be 3D printed in days, not weeks.
Markforged Onyx Matrix
Onyx (carbon-filled nylon) base material with continuous carbon fibre strands routed exactly where load is highest.
Tunable Stiffness
Fibre routing, fill density and reinforcement layers are specified per-part — you only pay for the strength you actually need.
Fast Iteration
Test a load-bearing prototype in 48 hours instead of 4 weeks of CNC tooling and machining.
Our Workflow
How a CCF job is engineered
Send the part & load case
Upload your CAD plus a description of the load — direction, magnitude, frequency. We'll engineer the fibre layup to match.
Fibre routing design
Our engineers specify isotropic, concentric or unidirectional fibre paths and reinforcement density per layer.
Print on Markforged
Onyx (carbon-filled nylon) base extrudes alongside continuous carbon, fibreglass or Kevlar — fused at every layer.
Inspect, finish, dispatch
Parts are dimensionally checked, post-cured if specified, and shipped with a documented fibre layup spec.
What we deliver
Continuous fibre reinforcement, engineered per part
Onyx base · Carbon / glass / Kevlar routing · Documented load capacity
Continuous carbon fibre 3D printing is fundamentally different from chopped-fibre filament. A continuous strand of aerospace-grade fibre is laid down between layers of Onyx (carbon-filled nylon), bonded by the matrix, and routed exactly where stress is highest. The result is an engineered composite part — not a generic printed plastic — with strength-to-weight that rivals milled aluminium and lead times measured in days, not weeks.
- Markforged Onyx, X7 and Mark Two systems in-house
- Continuous carbon, fibreglass, Kevlar and HSHT fibreglass
- Engineer-routed fibre paths matched to your specific load case
- Documented stiffness, tensile and impact properties per part
- Build envelope up to 330 × 270 × 200 mm
- Confidential handling under NDA for defence, motorsport and IP-sensitive work
Our 3D printing services
Explore our 3D printing services
3D Printing Services
Industrial and business 3D printing across FDM, SLA, SLS, MJF and metal — for engineers, procurement and product teams Australia-wide.
Learn more ↗SLA 3D Printing
Ultra-smooth, high-detail resin 3D printing for visual prototypes, master patterns and display models.
Learn more ↗FDM 3D Printing
Tough thermoplastic parts for jigs, housings, brackets and durable functional prototypes.
Learn more ↗Rapid Prototyping
Fast, iterative prototypes and functional parts to validate your design before committing to tooling.
Learn more ↗Low-Volume Production
Production-grade short runs from 1 to 10,000+ parts without the cost of full injection tooling.
Learn more ↗Exhibition & Display Models
Large-format 3D printed exhibition models, product display models and show pieces — printed, finished and brand-coloured.
Learn more ↗Materials
Markforged composite system
Onyx base material with four reinforcement options — chosen per part to match load, environment and budget.
Onyx (Carbon-Filled Nylon)
BaseThe default base material. Tough, dimensionally stable carbon-filled nylon — already stronger than ABS before continuous reinforcement.
Continuous Carbon Fibre
ReinforceAerospace-grade carbon fibre tow routed through Onyx for maximum stiffness-to-weight in load-bearing parts.
Continuous Fibreglass
ReinforceLower-cost reinforcement with similar tensile strength to carbon fibre but lower stiffness — ideal for higher-elongation parts.
Continuous Kevlar
ReinforceAramid reinforcement for impact-resistant parts that need to bend and recover rather than fracture.
High-Strength HSHT Fibreglass
HeatHeat-stable fibreglass that retains stiffness up to ~150 °C — for under-bonnet and heated-tooling applications.
Industries we serve
Where continuous carbon fibre earns its keep
Structural parts where stiffness matters, weight matters, and waiting four weeks for a CNC slot doesn't work.
UAV & Drone Frames
Lightweight load-bearing chassis, payload mounts and propeller guards stiff enough to fly serious payloads.
Motorsport Brackets
Sub-aluminium-weight brackets, mounts and ducting for racing applications where every gram counts.
Manufacturing Fixtures
Robot end-effectors, work-holding jigs and inspection fixtures with metal-grade stiffness and zero tooling cost.
Defence Prototypes
Confidential structural prototypes printed under NDA — fast iteration for weapon mounts, equipment housings and field-deployable kit.
Mining Spares
Replacement brackets and handles for remote-site equipment when OEM lead time is months and downtime is unacceptable.
Research Equipment
Custom rigs, sensor mounts and one-off test fixtures for universities and R&D labs.
Showcase
Recent continuous-fibre work
Continuous carbon fibre bracket replacing a 6061 aluminium part — 40% lighter.
Onyx + CCF UAV chassis printed for an Australian drone integrator.
Markforged X7 alongside our FDM and SLS fleet.
FAQ
Frequently asked questions
Explore more
More from Forge Labs
Ready to start your project?
Upload your file or send a quick brief — most quotes come back within 4 working hours, with parts dispatched Australia-wide from our Sydney workshops.