LMPAEK study ↗
Large-format trials with unreinforced and carbon-fiber-reinforced LMPAEK examine how interlayer temperature control changes bond strength.
Material savings assumptions
Make the savings estimate
fit your part.
Extra thickness adds cost to every part. When weak layer bonds are the reason for that thickness, stronger bonding can create room to use less material. The calculator helps you put a value on that opportunity.
Open the material savings calculator ↗Start with your material.
Selecting a polymer loads a starting price and material reduction. Change the price to what you pay for the pellets you use, and adjust the reduction to the weight your design could save.
| Material | Pellet price | Material reduction |
|---|---|---|
| PP/PE | €8/kg | 20% |
| PEI / ULTEM | €50/kg | 55% |
| PESU | €35/kg | 20% |
| LM-PAEK | €125/kg | 40% |
| PA6 / Nylon | €12/kg | 20% |
| PETG | €8/kg | 15% |
| ABS | €8/kg | 20% |
| PLA | €8/kg | 10% |
| PC | €12/kg | 20% |
| PET | €8/kg | 30% |
| HIPS | €13/kg | 15% |
These are starting estimates, informed by published strength data where available. Confirm the price and achievable reduction for your specific grade and part. For a fiber-filled material, select the base polymer and enter the figures for the compound you use.
Stronger bonds can mean a thinner section.
For a section sized by a tensile load, higher strength reduces the cross-sectional area needed to carry that load. The PEI example uses a 48 MPa starting value and a 110 MPa target.
1 − 48 ÷ 110 = 56.4% less area
The calculator rounds this down to a 55% material-reduction estimate. The reference values use different strength measures, so treat this as a sizing example and confirm it with comparable tests for your grade and process.
The saving applies only to the material your design can remove. If half the original part weight can become thinner, the same calculation gives a 28.2% reduction for the whole part. Material needed for stiffness, buckling resistance, handling or machining still has a job to do.
Use research to understand the bond.
Published studies show how temperature and processing conditions affect layer strength. They help you choose what to control and test; the material reductions in the calculator remain design estimates for your own part.
PA6-CF study ↗
A large-scale extrusion study connects surface temperature, microstructure and mechanical performance in carbon-fiber-reinforced PA6.