Caracol unveils high throughput xHF extruder

Caracol has announced the launch of its latest innovation, the high throughput xHF Extruder, premiering at JEC World 2025 in Paris. This new end effector is now a component to configure to the company’s composite Heron AM LFAM platform, boosting productivity with an extrusion rate of up to 75 kg per hour, while enhancing precision, and multi-material capabilities. The new solution can process two materials simultaneously thanks to a double chamber and custom nozzles, marking a significant leap forward in extra large scale 3D printing for the aerospace, marine, construction, and architectural sectors.

The xHF (Extra Flow) Extruder – engineered and patented to maximise throughput, precision, and material flexibility, with advanced plasticisation and thermal control – delivers:

• Minimised component stress and enhanced durability due to dual motor torque distribution.

• High volume production of large scale parts, thanks to exceptional speed and precision.

• Superior material plasticisation with four thermal control zones per each extrusion chamber.

• Compatibility with high performance composites thanks to an operating temperature up to 450°C.

• A compact size, with a balanced centre of gravity, ensuring an agile machine setup and high movement speed, with a maximised print volume

The xHF offers a combination of productivity and flexibility. By printing bi-material layers, the Heron AM platform can produce high performance composite parts in a more flexible and convenient way – combining, for example, a cost effective core material surrounded by a technical outer skin of high performance thermoplastics. This innovative feature cuts costs on macrostructures and maximises the advantages of each material used.

By equipping Heron AM with the xHF (Extra Flow) extruder, specifically engineered for extra large applications, Caracol is delivering the ideal solution for manufacturing ultra large components in several industries, such as:

• Construction and architecture: prefabricated structures and units, sustainable housing, and urban infrastructure,

• Marine and aerospace: large format moulds, models, and functional components like boat hulls.

• Industrial manufacturing: tooling, jigs, and custom designed composite extra large structures.

‘With this launch, we are redefining what is possible in large scale additive manufacturing,’ commented Giovanni Avallone, chief innovation officer and co-founder of Caracol. ‘Working within the industry as both a service bureau and a technology provider, we recognise the gap in the market for this high speed extrusion and advanced multi-material capabilities combination. This extruder will enable manufacturers to produce ultra large, high performance composite parts with greater efficiency and precision than ever before, opening up the benefits of AM to more industries without compromising on quality or material flexibility.’