3D Printer Filament Production Lines
The PP Series 3D printer filament production lines manufactured by Polmak Plastik are developed for producing filaments with precise diameter tolerances from thermoplastics such as PLA, PETG, ABS, PC, HIPS, PEEK, PEI and PPSU. Extending from laboratory and low-capacity production systems to high-speed industrial lines, the product range integrates extrusion, cooling, laser diameter measurement, servo-controlled haul-off, tension control, filament accumulation and automatic winding into a complete production line.
Polmak Plastik 3D Printer Filament Production Lines
The PP Series 3D printer filament production lines manufactured by Polmak Plastik are integrated production systems developed for the controlled melting, forming, cooling, measurement, drawing and winding of different thermoplastic raw materials.
The product family extends from the compact PP-25 models for product development and low-capacity production to the PP-35S, PP-45S and PP-50S models for medium and high-capacity industrial production. The PP-45H high-temperature filament production line is offered for engineering plastics such as PEEK, PEI and PPSU that require high processing temperatures.
The dimensional stability, surface quality, roundness, mechanical properties and winding consistency of a filament depend not only on extruder capacity but also on the balanced operation of the complete production line. For this reason, Polmak Plastik filament production lines integrate critical process stages such as raw material feeding, drying, extrusion, die forming, conditioning, cooling, laser measurement, servo haul-off, accumulation and winding.
In addition to standard filament production, each line can be configured according to the raw material, required filament diameter, production capacity, cooling method and automation level of the project.
PRECISE AND CONSISTENT FILAMENT PRODUCTION
Diameter variation must be kept as low as possible in 3D printer filaments. Fluctuations in filament diameter change the quantity of material supplied to the 3D printer and may cause irregular printing surfaces, weak bonding between layers, nozzle blockages and dimensional deviations.
In PP Series lines, the filament diameter is continuously monitored with a non-contact laser scanning system. Under the targeted production conditions, the PP-35S, PP-45S, PP-45H and PP-50S models can provide a filament diameter tolerance of plus or minus 0.02 mm. The specified tolerance for the PP-25S and PP-25H models is plus or minus 0.03 mm.
Integration of the laser measuring system with the haul-off and line control helps the system respond quickly to changes in filament diameter. Automatic feedback and PID control options allow the haul-off speed to be adjusted according to process conditions. This supports more consistent filament diameter throughout production.
The standard filament diameter can be configured as 1.75 mm. Depending on the model and die selection, solutions can also be developed for 2.85 mm, 3.00 mm or other customer-specific filament diameters.
CONTROLLED EXTRUSION TECHNOLOGY
PP Series production lines use single-screw extrusion technology. The screw diameter and motor power are selected according to the target capacity of the model and the raw material group to be processed.
The screw and barrel can be manufactured from nitrided 38CrMoAlA steel or alloy materials suitable for high-temperature applications. Nitriding increases the wear resistance of the screw and barrel surfaces and supports stable, long-term production.
Ceramic heaters, multi-zone temperature control and air-cooled barrel sections provide controlled melting of the raw material throughout the process. Temperature zones, haul-off operation, winding parameters and other line functions can be monitored through the PLC control system.
Filament dies manufactured from S136 steel offer good surface quality and an easy-to-clean structure, simplifying product changes between different formulations. Special dies and alloy screw and barrel options can be used for high-temperature applications.
RAW MATERIAL FEEDING AND DRYING
Correct drying of the raw material before production is one of the most important factors affecting filament quality. Hygroscopic materials such as PLA, PETG, PC and PEEK can absorb moisture from the atmosphere. Extrusion of wet raw material may cause surface defects, bubbles, discoloration and deterioration of mechanical properties.
PP Series lines are available with automatic vacuum feeding and drying hopper options. Depending on the model and production capacity, drying hoppers with capacities of 12 kg, 50 kg or 100 kg can be used. On high-capacity lines, the automatic feeding system transfers the material continuously from the drying unit to the extruder.
A 50 kg raw material mixer and vacuum packaging machine can also be integrated into the system when required by the material preparation and packaging process.
COOLING AND FILAMENT CONDITIONING
Controlled cooling of the filament after the die is critical for diameter stability and roundness. Excessively rapid or unbalanced cooling may cause internal stress, ovality and surface defects.
Depending on the characteristics of the processed material, the PP Series can be configured with water cooling, temperature-controlled hot and cold water conditioning, or hot and cold air cooling.
The PP-25S uses a stainless-steel hot and cold water tank. The PP-25H combines air and water cooling sections, providing more flexible process control for materials with different cooling characteristics.
The PP-35S and PP-45S models use a temperature-controlled hot water tank and a stainless-steel cold water tank. The tanks can be adjusted vertically and horizontally, helping the filament follow the correct path through the production line.
The PP-45H high-temperature line uses a hot and cold air conditioning system instead of a conventional water bath. Four-metre hot-air and cold-air sections provide gradual cooling of high-temperature engineering plastics.
The PP-50S high-speed production line includes two constant-temperature water tanks, a six-metre cold-water tank and a stainless-steel drying section. This configuration helps manage filament temperature and surface moisture at high line speeds.
SERVO-CONTROLLED HAUL-OFF AND WINDING
Haul-off speed is one of the main process parameters that directly affects filament diameter. Servo-controlled haul-off units used in PP Series lines move the filament at a controlled and stable speed.
Medium and high-capacity models can be equipped with a servo haul-off system containing four sets of rollers. The servo motor and PLC control help coordinate the extrusion output with the haul-off speed.
Servo-controlled winders wind the filament evenly and consistently onto the spool. The pneumatic chuck simplifies spool changes, while the automatic traversing system distributes the filament evenly across the spool surface.
The horizontal filament accumulator acts as a buffer between the haul-off and winder. It helps production continue more smoothly during spool changes. Depending on the model, the accumulator may have a length of eight or twelve metres and provide a filament storage capacity of between 200 and 360 metres.
PP-25S
The PP-25S is a compact filament extrusion line designed for product development, laboratory work, filament formulation trials and low-capacity commercial production.
The model uses a single-screw extruder with a 25 mm screw diameter, 28:1 L/D ratio and 1.5 kW extruder motor. The three-zone ceramic heating system consists of 500 W, 500 W and 600 W heaters.
The line includes a raw material drying hopper, extruder, S136 steel die, stainless-steel cooling tank, laser diameter measuring device, servo-driven haul-off, tension control system and winder.
The model is suitable for standard filament diameters of 1.75 mm and 3.00 mm, with a specified diameter tolerance of plus or minus 0.03 mm. The haul-off speed can be adjusted between 0 and 30 metres per minute. The automatic tension detection system helps adjust the winding speed according to filament movement.
PP-25H HIGH-TEMPERATURE FILAMENT PRODUCTION LINE
The PP-25H combines the compact structure of the PP-25S with more advanced cooling and automation features. The system includes a PLC-controlled 25 mm single-screw extruder, air-cooling section, water-cooling tank, laser diameter measuring system with automatic feedback, servo haul-off, tension control and servo winder.
The screw diameter is 25 mm, the L/D ratio is 28:1 and the extruder motor power is 1.5 kW. A three-zone ceramic heating system is used. Standard filament diameters are 1.75 mm and 3.00 mm, and the specified production tolerance is plus or minus 0.03 mm.
The combination of air and water cooling allows the process to be adjusted according to the cooling behaviour of different materials. The laser measuring system with automatic feedback provides more advanced diameter control together with the servo haul-off and winder.
PP-35S
The PP-35S is developed for flexible, medium-scale filament production. Suitable for processing PETG, ABS, PLA, PC, HIPS and similar thermoplastics, the model offers a production capacity of between 8 and 15 kg per hour, depending on the raw material and process conditions.
The model uses a single-screw extruder with a 35 mm screw diameter, 28:1 L/D ratio and 7.5 kW motor. The extruder has four heating zones and four cooling zones and is managed through a PLC-based control system.
The PP-35S can be equipped with a constant-temperature water tank, cold-water tank, dual-axis laser diameter measuring system, servo haul-off, servo winder, eight-metre horizontal filament accumulator and automatic feeding and drying hopper.
The standard production diameter is 1.75 mm. Depending on the die and process configuration, 2.85 mm or other diameters can also be produced. The specified filament diameter tolerance is plus or minus 0.02 mm.
The line is approximately 14 metres long, 1.5 metres wide and 2.25 metres high. The installed power is approximately 20 kW, while estimated power consumption during normal operation is approximately 10 kW.
PP-45S
The PP-45S is developed for filament manufacturers requiring higher production capacities. Suitable for materials such as PETG, ABS, PLA, PC and HIPS, the model provides a production capacity of between 20 and 25 kg per hour.
The line uses a single-screw extruder with a 45 mm screw diameter, 28:1 L/D ratio and 11 kW extruder motor. Four-zone heating and air cooling support controlled processing of the raw material.
A constant-temperature hot-water tank, six-metre cold-water tank, dual-axis laser diameter measuring system, servo haul-off, servo winder and eight-metre filament accumulator form the standard production flow.
The specified filament diameter tolerance of the PP-45S is plus or minus 0.02 mm. Depending on the material and filament diameter, the process speed is between 80 and 120 metres per minute.
The line is approximately 15 metres long, 1.5 metres wide and 2.25 metres high. The installed power is approximately 29 kW, while estimated operating consumption is between 12 and 14 kW.
PP-45H HIGH-TEMPERATURE FILAMENT PRODUCTION LINE
The PP-45H is a specialised line developed for producing filament from engineering plastics that require high processing temperatures. It can be configured for technical thermoplastics such as PC, PEEK, PEI and PPSU.
Depending on the material and process conditions, the production capacity ranges from 3 to 10 kg per hour. The targeted filament diameter tolerance is plus or minus 0.02 mm, while the process speed is approximately 10 to 50 metres per minute.
The system uses a single-screw extruder with a 45 mm screw diameter, 28:1 L/D ratio and 15 kW motor. The alloy screw and barrel system, high-temperature die and four-zone temperature control provide a process infrastructure suitable for high-performance engineering plastics.
A four-metre hot-air conditioning section and four-metre cold-air section provide gradual filament cooling. The line also includes a dual-axis laser measuring system, servo haul-off, servo winder, horizontal filament accumulator and automatic feeding and drying hopper.
The approximate line dimensions are 15 x 1.5 x 2.25 metres. The installed power is approximately 25 kW, while estimated operating consumption is between 10 and 12 kW.
PP-50S HIGH-SPEED FILAMENT PRODUCTION LINE
The PP-50S is the high-speed model developed for continuous, high-capacity filament production. It is particularly suitable for manufacturers targeting high productivity in PLA and PETG filament production.
Depending on process conditions, the model can reach a production capacity of 40 kg per hour. The standard filament diameter is 1.75 mm and can be customised for other diameters. The specified filament diameter tolerance is plus or minus 0.02 mm, while the line speed is between 180 and 350 metres per minute.
The PP-50S uses a single-screw extruder with a 50 mm screw diameter, 30:1 L/D ratio and 18.5 kW servo motor. The extruder has five heating zones and five air-cooling zones.
The line consists of two constant-temperature water tanks, a six-metre cold-water tank, three-section filament drying system, dual-axis laser diameter measuring device, 1.1 kW servo haul-off, high-speed servo winder and twelve-metre horizontal filament accumulator.
The horizontal accumulator contains 15 fixed and 14 moving rollers and can store up to 360 metres of filament. This feature helps reduce the effect of spool changes on the high-speed production process.
The approximate installation area of the PP-50S is 20 x 1.5 x 2.25 metres. The installed power is approximately 45 kW, while estimated power consumption during normal operation is approximately 22 kW.
HOW TO SELECT THE RIGHT MODEL
Selection of the correct filament production line should not be based solely on the target capacity. The melting temperature, moisture sensitivity, viscosity and filler content of the raw material must be evaluated together with the target filament diameter, frequency of formulation changes, required tolerance and daily operating time.
The PP-25S is a compact and economical solution for formulation development and low-capacity production.
The PP-25H is suitable for users requiring more advanced cooling, automatic diameter feedback and servo winding.
The PP-35S is intended for companies seeking flexible, medium-capacity production with different standard thermoplastics.
The PP-45S is developed for manufacturers targeting serial production capacities of between 20 and 25 kg per hour.
The PP-45H is a specialised solution for high-temperature engineering plastics such as PEEK, PEI and PPSU.
The PP-50S is designed for high-speed PLA and PETG filament production with capacity requirements reaching 40 kg per hour.
PROJECT-SPECIFIC FILAMENT PRODUCTION SOLUTIONS
Polmak Plastik approaches a filament production line not simply as a collection of separate machines but as an integrated process extending from raw material feeding to the finished filament spool.
The appropriate line configuration is determined by evaluating the raw material, target production capacity, filament diameter, tolerance requirements, factory layout and required automation level. Depending on the application, the project may include a raw material mixer, vacuum feeding system, drying hopper, alternative cooling systems, laser diameter measurement, servo haul-off, filament accumulator, servo winder and vacuum packaging equipment.
Installation, commissioning, operator training, technical documentation, maintenance and after-sales services support the sustainable operation of the production line.
Technical values may vary depending on the raw material, filament diameter, additive content, formulation, cooling conditions and selected machine configuration. Final capacity and line specifications are determined following a detailed project evaluation.
