AON3D Hylo High-Temperature Industrial 3D Printer

Industrial 3D Printing for PEEK, ULTEM™, PEKK and Advanced Composites

The AON3D Hylo is a high-temperature industrial 3D printer built for manufacturing functional parts from high-performance polymers and fibre-reinforced composites. With a 650 × 450 × 450 mm build volume, 250°C heated chamber, 500°C nozzle temperature, dual independent composite-ready extruders, and an open material system, Hylo is designed for demanding applications where part performance, repeatability and production throughput matter.

Hylo combines high-temperature hardware with automated calibration, controlled material handling, in-process monitoring and AON3D Basis™ software. The result is a more controlled workflow for producing large, strong and complex parts from materials including PEEK, ULTEM™ 9085, ULTEM™ 1010, PEKK, carbon-fibre-reinforced polymers and other engineering materials.

Open Material System

Hylo provides open access to high-performance 3D printing materials without material unlock fees or hardware upgrades. Engineers can work with qualified material profiles or develop processes for custom polymers and other materials using Hylo's open process controls.

Compatible materials include PEEK, PEKK, ULTEM™/PEI, PPSU, PSU, PVDF, PC, nylon, PAEK, PEBA and fibre-reinforced variants, along with a broad range of conventional engineering and support materials.

High-Temperature Printing

Hylo is engineered around the thermal requirements of demanding polymers. Its heated build chamber reaches 250°C, with a 250°C build platform and extrusion temperatures up to 500°C.

This thermal capability helps maintain the controlled printing environment required for high-performance polymers such as PEEK, ULTEM™ and PEKK.

Composite-Ready Dual Extrusion

Hylo uses dual independent, composite-ready extruders for printing engineering polymers and fibre-reinforced materials. AON3D reports tensile strength exceeding 140 MPa and tensile modulus of 11 GPa for chopped carbon-fibre-filled PEEK under specified conditions.

Independent extruders also support complex geometries with soluble, detergent-soluble or breakaway support materials, as well as duplication-mode production workflows.

High Throughput for Production Applications

With print speeds up to 500 mm/s and material flow rates up to 360 cm³/h, Hylo is designed to reduce print times for large functional parts and production work.

Duplication mode can also be used to increase output when producing repeated parts, making Hylo suitable for manufacturing environments where throughput matters as much as print quality.

Automated Calibration and Material Handling

Hylo automates many of the setup and monitoring tasks associated with high-temperature 3D printing. Optical nozzle inspection, offset calibration, independent active-leveling extruders and linear encoders help maintain repeatable printing conditions.

The integrated material management system includes humidity-controlled storage, automated material loading and changeover, filament feed monitoring and filament diameter compensation.

In-Process Monitoring and Quality Verification

More than 25 integrated sensors monitor the printing process and collect production data. Hylo's process logs can be analyzed through AON3D Basis™ to identify print issues and verify part quality.

The system can detect issues such as warping, debris inclusions, over- or under-extrusion and other print defects, providing additional visibility into the manufacturing process.

AON3D Basis™ AI-Driven Optimization

Basis™ uses AI-driven process simulation and polymer physics to generate dynamic print settings based on the part geometry, material and printing conditions.

Instead of applying identical settings throughout a part, Basis can optimize process parameters millimetre by millimetre to improve interlayer bonding, reduce thermally related defects and maximize part performance. AON3D reports parts up to 85% stronger in testing with optimized processes compared with default print settings.

Built for Functional Parts and Advanced Manufacturing

AON3D Hylo is suited to applications where conventional desktop 3D printers cannot provide the required combination of temperature, material capability, part size or process control.

Typical applications include:

• Functional prototypes in high-performance polymers

• End-use and production parts

• Large PEEK and PEKK components

• ULTEM™ 9085 and ULTEM™ 1010 parts

• Carbon-fibre and glass-fibre reinforced components

• Jigs, fixtures and manufacturing aids

• Replacement and low-volume production parts

• Aerospace and defence applications

• Automotive and transportation components

• Industrial tooling and manufacturing

For organizations evaluating an industrial 3D printer for PEEK, ULTEM™, PEKK or composite materials, Hylo combines a large build volume and high-temperature platform with open material access, automated operation and process monitoring.

Need help determining whether Hylo is the right platform for your materials or application? Contact 3D Printing Canada for product and application support.

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