3D PRINTER LFAM - POLYMER LARGE FORMAT - CARACOL ADDITIVE MANUFACTURING

3D printing is an innovative manufacturing process that builds three-dimensional objects through the extrusion of material (plastic, metal, ceramics, and many more) layer upon layer, starting from a digital model. Also known as Additive Manufacturing, 3D printing is opposed to the traditional “subtractive” manufacturing methods that machine the final components by cutting away material. This new process leads to a more efficient production with less material wastage and to a greater design freedom, allowing to experiment with complex geometries that were once considered challenging or impossible to produce through conventional means.

There is a distinction between Additive Manufacturing and 3D printing, although the terms are often used interchangeably. Additive Manufacturing (AM) is the process that encompasses various techniques, with 3D printing being one of them. Additive Manufacturing refers to the method of creating objects by adding material layer by layer, based on a digital model. This process eliminates material waste and allows for complex and customized designs. 3D printing specifically refers to the Additive Manufacturing technology that uses printers to create physical objects from digital files. In essence, 3D printing is a subcategory of Additive Manufacturing.

LFAM stands for “Large Format Additive Manufacturing“, a cutting-edge technology within the realm of Additive Manufacturing. It refers to the capability of producing significantly larger objects and components, compared to traditional Additive Manufacturing techniques. LFAM systems, such as Caracol integrated platform HERON AM, are used to create large-scale components by layer-by-layer material deposition based on digital designs. This technology has gained attention across industries such as architecture and construction, automotive, aerospace, marine and railway. By enabling the creation of entire building components, vehicle parts, and even aircraft structures and tooling, LFAM pushes the boundaries of design possibilities and manufacturing efficiency.

Print big, print better with Heron AM, the integrated platform that will drive you to the next manufacturing revolution. Join the companies all around the globe who are introducing efficiency, flexibility, and sustainability in their supply chains, thanks to the large format additive manufacturing technologies for composites and thermoplastics.

Revolutionizing manufacturing processes with cutting-edge 3D printed applications

Modularly configure Heron AM, to fit your industrial manufacturing needs with no limits in scale, shape, and material

APPLICATION-FIRST APPROACH
Our large format 3D printing technology is designed with end-user needs at its core, developed from years of experience in producing parts for clients. We focus on ensuring high production quality and continuity for advanced industrial applications.

HIGH-PRODUCTIVITY PLATFORM
Our modular all-in-one platform integrates hardware, software, and automation to enhance flexibility, efficiency, and sustainability in manufacturing, and improve production control while reducing risks, with Caracol providing quick and reliable support.

QUALITY AS A SERVICE
Heron AM meets the highest production standards and is the first to be certified for demanding industrial requirements. We deliver precise and reliable technology, supported by comprehensive services to help you maximize your machines' potential.



Caracol’s extruders process composite fiber-reinforced thermoplastic pellets, with models tailored to different manufacturing needs—balancing performance, quality, and cost-efficiency.

xHigh Flow (xHF): Compact, durable, and Caracol’s highest-throughput extruder, enabling precise bi-material printing for large-scale, advanced industrial applications.

High Flow (HF): Robust and fast, ideal for reducing print times while maintaining material versatility and quality.

High Versatility (HV): Flexible and adaptable across a wide range of industrial applications.

High Accuracy (HA): Lightweight and precise, perfect for fine detailing, quality finishes, and agile movement.

Robotics
Leveraging the flexibility of the 6+ axes movements, robotic arms allow Heron AM to manufacture parts with very complex geometries, including non-planar tool paths, and unconventional slicing at different angles such as 45° or 60. Robotics also allows to modularly set up the system with different arm sizes to satisfy specific needs on applications or production area. Furthermore, arms can be extended on the x-axis with a rail or on the y-axis adding a plinth. To provide the best automation solution, Heron AM can be setup with robots from KUKA to FANUC and ABB.

Control System
The Heron AM platform features a user-friendly HMI and a self-standing Control Unit for precise extruder and process control, as well as efficient side machine operations. For enhanced functionality, the system can include a dedicated screen for smart monitoring and IoT integration.

To ensure modularity and flexibility, Heron AM platforms are equipped with the Caracol Control Cabinet, a centralized unit compatible with multiple, industrial end-effectors through plug-and-play logic. This enables customization for diverse applications with ease.

Software
Caracol developed its software suite Eidos Manufacturing, with years of experience in Design for LFAM, slicing strategies, and robotic cinematics. The software suite completes Caracol’s LFAM hardware, ensuring full control and flexibility on the process.
Eidos Builder allows users to seamlessly transform 3D models into optimized part programs, programming even complex tool paths in few steps, and obtain maximum control on all the production parameters. Eidos IoT platform is a cloud-based solution for live process and machine monitoring, efficient data handling for analysis, remote technical support and decision-making, that enhances the manufacturing process’ quality and repeatability of Caracol’s LFAM platforms.

Printing Beds
The printing bed is key to successfully print parts. Caracol has developed several models to fit all needs, customizable in terms of size.
The aluminum frame structure with interchangeable top panels, is a convenient and flexible set up. With a simple brim or raft it ensures stability throughout the job. With the simple stainless-steel bed, high rigidity and planarity, anti-corrosion, and durability are guaranteed.
The patented automatic bed for unmanned part clamping and unloading was designed by Caracol to guarantee automated production with great part stability. The aluminum slats structure allows mechanical gripping of the first layer. Rotating at the end of each cycle and releasing the printed part autonomously, this printing bed is ideal for continuous production.

Feeding System
The direct and continuous supply of material is possible thanks to the automated material feeding system, developed by Caracol. A drying unit is connected to the extruder to input pellets during the whole printing cycle, avoiding manual operations that could stop the machine’s job.
Pellets and shreds are stored at the right humidity and temperature and dried for best performance and quality. Its capacity of 50-80 Kg (110-176 lb) can be extended with direct connection to a bigger storage or with multiple material feeding units, to facilitate production-continuity for unlimited hours.

Enclosures
Perimetral protections are needed to operate with the optimal printing conditions and safety. Enclosures allow to control environmental parameters, such as temperature and humidity, and track them to guarantee process repeatability and quality. Customers can opt for different configurations: open air Safety Light Curtains and Protective Cages; Advanced Enclosure, developed to control all environmental parameters, monitor printing, guarantee safety, process repeatability, and quality; Portable Container Unit, to set up manufacturing of parts in any location.

Tool changer
Thanks to its dedicated automation and control suite, Heron AM supports an automatic tool changer compatible with multiple industrial end-effectors. This enables seamless switching between Caracol’s extruders or a milling head within the same production cycle—boosting versatility, reducing downtime, and maximizing efficiency.

MATERIALS
PET-G | ABS | POLYPROPYLENE | ASA | PLA | POLYCARBONATE | POLYETHERMIDE | HDPE | POLYAMIDE 6 | TPE | CARBON FILLED | GLASS FILLED | VIRGIN and RECYCLED MATERIALS

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