When it comes to functional, load-bearing, and impact-resistant parts, few 3D printing materials can rival nylon, carbon fiber-reinforced nylon (CF nylon), and polycarbonate (PC). These engineering-grade filaments are known for their toughness, durability, and heat resistance, making them ideal for demanding applications in robotics, automotive, aerospace, and industrial prototyping.
However, these filaments are also some of the most difficult to print successfully. Without proper preparation, tuning, and hardware, prints are likely to fail due to warping, layer separation, or poor bed adhesion.
This comprehensive guide covers how to 3D print tough parts using nylon, CF nylon, and polycarbonate — from hardware upgrades to slicer settings and print environment control.
Why Use Nylon, CF Nylon, and Polycarbonate?
Nylon
- Flexible and tough
- Good chemical resistance
- High impact strength
- Moderate heat resistance (up to ~120°C)
CF Nylon
- Nylon infused with chopped carbon fibers
- Much stiffer and more dimensionally stable than pure nylon
- Less warping
- Excellent strength-to-weight ratio
Polycarbonate (PC)
- Extremely high impact strength
- High heat resistance (up to ~140°C or more)
- Strong interlayer bonding when printed correctly
- Optical clarity in natural form
Each material is suited for high-performance parts, but requires careful setup for reliable results.
Required Hardware for Tough Filament Printing
1. All-Metal Hotend
Most of these filaments require extrusion temperatures above 250°C. PTFE-lined hotends degrade at those levels and may release harmful fumes. Use an all-metal hotend capable of at least 280°C.
2. Heated Bed
A stable bed temperature is essential to minimize warping:
- Nylon: 60°C – 80°C
- CF Nylon: 70°C – 90°C
- Polycarbonate: 90°C – 110°C
3. Enclosure
An enclosure traps heat around the print, reducing layer separation and improving first-layer adhesion. Enclosures are especially important for PC and nylon, which are highly sensitive to drafts and temperature fluctuations.
4. Hardened Steel Nozzle
CF nylon is abrasive and will rapidly wear down brass nozzles. Use a hardened steel or ruby-tipped nozzle for all abrasive filaments.
5. Filament Dryer
All three materials are highly hygroscopic. Printing them wet leads to stringing, bubbling, poor surface finish, and weak layers. Use a filament dryer to remove moisture before and during printing.
Best Print Settings for Each Material
Nylon
Nozzle Temp: 240°C – 260°C
Bed Temp: 70°C – 90°C
Cooling Fan: Off or 10%
Print Speed: 30mm/s – 60mm/s
Retraction: Moderate (2mm – 5mm depending on extruder)
Tips:
- Use glue stick, PVA slurry, or Garolite (G10) sheet for adhesion.
- Dry filament thoroughly before use.
- Increase enclosure temp or ambient heat to reduce warping.
CF Nylon
Nozzle Temp: 250°C – 270°C
Bed Temp: 75°C – 90°C
Cooling Fan: Off
Print Speed: 40mm/s – 70mm/s
Retraction: Shorter settings with hardened nozzles
Tips:
- Requires less warping control than pure nylon due to fiber content.
- Use reinforced build plates (PEI, Garolite) for bed adhesion.
- Use abrasive-resistant nozzles and check wear over time.
Polycarbonate
Nozzle Temp: 260°C – 300°C
Bed Temp: 90°C – 110°C
Cooling Fan: Off
Print Speed: 20mm/s – 50mm/s
Retraction: Low speed, 1mm – 2mm in direct drive setups
Tips:
- Must be printed in an enclosure to avoid splitting.
- Use adhesives like PC-specific glue, PEI sheets, or polycarbonate-compatible bed surfaces.
- Handle with care when removing from the bed — PC bonds tightly.
Slicer Tuning for Tough Materials
Wall and Infill Settings
- Use 3 to 4 wall lines for strength
- 50% or higher infill for load-bearing parts
- Gyroid or cubic infill patterns offer better internal strength
First Layer Settings
- Increase first layer height slightly (e.g., 0.25mm)
- Lower first layer speed to 20mm/s for better adhesion
- Raise nozzle temperature slightly for first layers (e.g., +5°C)
Bridging and Overhangs
- These materials are not optimized for bridging due to low fan usage
- Design parts with minimal overhangs or use angled supports
Drying and Storage Guidelines
Nylon and CF Nylon:
- Dry at 70°C – 80°C for 6 to 12 hours
- Store in sealed bags with desiccants
- Print directly from a dry box if possible
Polycarbonate:
- Dry at 80°C – 90°C for 8 to 12 hours
- Degrades more quickly with moisture; keep airtight when not in use
Moisture is the leading cause of failed prints with tough materials. Even new filament may require drying before first use.
Design Considerations for Tough Prints
- Avoid sharp corners — fillets reduce internal stress.
- Orient parts so that the Z-axis does not carry primary load unless absolutely necessary.
- Use generous chamfers or radii for better interlayer adhesion and stress distribution.
- Design for functional tolerances — shrinkage and expansion rates are higher than with PLA or PETG.
Common Applications for Nylon, CF Nylon, and PC
- Functional prototypes
- End-use mechanical parts
- Gears, bearings, and bushings
- Custom brackets, jigs, and fixtures
- RC and drone components
- Enclosures for electronics under thermal or mechanical stress
These materials are trusted in professional and industrial workflows where standard consumer filaments fail.
Troubleshooting Tips for Tough Filaments
| Issue | Cause | Solution |
|---|---|---|
| Warping or curling | Bed temp too low or environment too cold | Increase bed temp, use enclosure |
| Layer separation (delamination) | Part cooling too high, ambient temp too low | Disable fans, use full enclosure |
| Nozzle clogs | Moist filament or improper retraction | Dry filament, reduce retraction distance |
| Poor bed adhesion | Wrong bed surface or low temp | Use Garolite, glue stick, or compatible adhesives |
| Weak interlayer bonding | Low extrusion temp or improper speed | Increase nozzle temp, reduce print speed |
Common FAQs About Tough Material Printing
Is a stock printer capable of printing nylon or PC?
Not reliably. Most stock 3D printers are not equipped with all-metal hotends, high-temp beds, or enclosures. Upgrades are required to print tough filaments consistently.
Which material is strongest: nylon, CF nylon, or polycarbonate?
Polycarbonate has the highest impact strength and heat resistance. CF nylon has the best strength-to-weight ratio and dimensional stability. Regular nylon is more flexible and better for applications requiring some give.
Can I print CF nylon with a brass nozzle?
No. CF nylon is highly abrasive and will wear down a brass nozzle quickly. Always use hardened steel or equivalent wear-resistant nozzles.
Why does my nylon print look stringy?
Nylon absorbs moisture quickly. Stringing is a symptom of wet filament. Dry the filament thoroughly and reduce print temperature slightly to minimize oozing.
How can I store these materials properly?
Use vacuum-sealed bags with desiccants or dry boxes. Keep them away from humidity, sunlight, and heat. Print directly from a dry box when possible.
Conclusion
Printing with engineering-grade filaments like nylon, CF nylon, and polycarbonate opens the door to professional-level, highly durable parts. These materials offer performance far beyond typical consumer filaments but require thoughtful preparation, upgraded hardware, and tightly controlled environmental conditions.
With the right setup — including an all-metal hotend, hardened nozzle, heated enclosure, and strict filament handling — you can consistently produce parts that rival injection-molded strength. Whether you are building functional prototypes or industrial-grade tools, mastering these materials is a major step toward professional 3D printing.