Generative design
to finished part.
Engineering-grade additive manufacturing for hardware, energy, robotics, and government programs. From DfAM and topology optimization to serialized production in high-performance polymers and composites.
13+
Materials
3
Process types
48hr
Typical turnaround
PA-CF · ACTIVE LAYER
Carbon-fiber reinforced nylon
±0.1 mm validated
From generative design
to certified part
Your dedicated additive manufacturing partner for hardware, energy, robotics, and government programs. We design it, we build it, we deliver it at production quality.
Energy & Industrial
Downhole tools, heat-resistant housings, chemical-barrier components, valve bodies
Robotics & Automation
End effectors, structural frames, sensor integration hardware, custom tooling
Government & Defense
Mission-critical structural parts, ITAR-adjacent supply, high-performance polymers
Hardware Companies
Product development, bridge production, design-to-manufacture, scale-up programs
Bring us a concept, sketch, or requirement — we handle design, optimization, and production.
Generative Design & DfAM
Transform a concept, legacy CAD, or rough sketch into topology-optimized, additive-native geometry. We analyze load paths, eliminate mass, and validate printability before a gram of material is used.
- Topology optimization
- Load path & stress analysis
- Mass reduction targets
- Print-ready geometry delivery
Rapid Prototype Sprint
First articles in 48–72 hours. Side-by-side material comparisons, design iterations, and a full dimensional inspection report — so you commit to a validated design, not a guess.
- 48–72 hr first articles
- Material comparison testing
- Multiple design iterations
- Dimensional inspection report
Production Program
Serialized production runs from 10 to 10,000+ parts with consistent quality, material certification documentation, and supply-chain reliability that program managers can build schedules around.
- 10–10,000+ unit runs
- Material certification docs
- First article inspection (FAI)
- Ongoing supply agreement
Bring your geometry — we manufacture to spec with full material and process documentation.
Engineering Polymer Print
ASA, PC, ABS, PETG, and Nylon for housings, enclosures, brackets, and light-duty structural hardware across all sectors.
- Bambu H2C / H2S platform
- Fast 3–5 day turnaround
- UV-resistant ASA option
- Complex internal geometries
Structural Composite Print
PA-CF, PC-CF, PPS-CF, and PHAT-CF for load-bearing, high-stiffness components operating under sustained thermal and mechanical stress.
- VisionMiner 22 IDEX v4
- Hardened wear nozzles
- Highest FFF stiffness-to-weight
- Carbon fiber reinforcement
Precision Resin Part
Formlabs Form 4 / 4L for gears, jigs, optical mounts, and any part requiring ±0.1 mm tolerances with a smooth, isotropic surface finish.
- ±0.1 mm tolerances
- Tough 2000 / Rigid 10K / High Temp
- Smooth isotropic surface
- Complex internal geometry
High-Temp & Exotic Polymers
PEEK, ULTEM, PPSU, and PEKK for aerospace, energy downhole, medical device, and government programs where standard polymers cannot survive the environment.
- 500 °C nozzle capability
- PEEK / ULTEM / PPSU / PEKK
- Biocompatible material options
- Certified material stock
Right material,
right part, first time
Every polymer we run is selected for an engineering purpose — not because it was cheapest or easiest. Specs sourced from official datasheets, not marketing copy.
Polycarbonate
PC
Impact champion
Optically clear-capable thermoplastic with outstanding impact resistance and moderate heat resistance. Ideal for enclosures, optical brackets, and structural housings.
Impact
34.8 kJ/m²
Flex Strength
108 MPa
Flex Modulus
2310 MPa
HDT
117 °C
Acrylonitrile Styrene Acrylate
ASA
UV-resistant outdoor workhorse
All-weather engineering polymer with inherent UV stability. No yellowing or embrittlement after extended outdoor exposure. The go-to for external drone and sensor housings.
Impact
41.0 kJ/m²
Flex Strength
65 MPa
Flex Modulus
1920 MPa
HDT
100 °C
FFF · CompositeNylon + Short Carbon Fiber
PA-CF
Structural lightweight champion
Short carbon-fiber-reinforced nylon delivering the highest stiffness-to-weight available in FFF. Printed drone arms and robot frames that meaningfully reduce flex under load.
Flex Strength
151 MPa
Flex Modulus
5460 MPa
HDT
186 °C
Density
1.12 g/cm³
FFF · CompositePolycarbonate + Carbon Fiber
PC-CF
Extreme impact + heat
The toughest FFF composite we run. Combines PC's legendary impact toughness with CF stiffness for parts that face both shock loading and elevated temperatures.
Flex Strength
131 MPa
Flex Modulus
5320 MPa
HDT
205 °C
Density
1.24 g/cm³
FFF · High-TempPolyphenylene Sulfide + Carbon Fiber
PPS-CF
Chemical & thermal fortress
Semi-crystalline high-performance composite with outstanding resistance to solvents, acids, and continuous heat up to 220 °C. Near-zero moisture absorption preserves dimensional stability in harsh environments.
Flex Strength
210 MPa
Flex Modulus
14000 MPa
Cont. Use Temp
220 °C
Moisture Abs.
< 0.02 %
High-Temperature Polyamide + Carbon Fiber
PHAT-CF
Next-gen nylon composite
Elevated-glass-transition polyamide with carbon fiber reinforcement engineered for sustained thermal and mechanical loads well beyond standard nylons. Bridges the gap between PA-CF and PEEK in cost-performance.
Flex Strength
195 MPa
Flex Modulus
11500 MPa
HDT
240 °C
Tg
~ 180 °C
FFF · NylonPolyamide 6 (PA6)
Nylon 6
Tough, versatile workhorse
The most widely used engineering nylon. Excellent fatigue resistance, high impact toughness, and broad chemical resistance. Ideal for moving parts that need to absorb repeated loads without cracking.
Tensile Strength
85 MPa
Flex Modulus
2900 MPa
Melting Point
220 °C
Moisture Abs.
~2.5 %
FFF · NylonPolyamide 12 (PA12)
Nylon 12
Flexible, stable, fuel-proof
Long-chain nylon with the lowest moisture absorption of the PA family, delivering superior dimensional stability and flexibility. Excellent resistance to fuels, oils, and hydraulic fluids — a favourite for SLS powder sintering as well as FFF.
Tensile Strength
52 MPa
Flex Modulus
1590 MPa
Melting Point
178 °C
Moisture Abs.
~0.25 %
Thermoplastic Polyurethane 95A
TPU
Rubber-flex vibration absorber
Shore 95A elastomer that combines rubber-like flexibility with FFF printability. Outstanding energy absorption and abrasion resistance — the go-to for vibration isolators, cable strain relief, and soft-touch grips on robotics hardware.
Tensile Strength
40 MPa
Elongation
400 %
Shore Hardness
95A
Density
1.22 g/cm³
Tough 2000
ABS-like functional prototypes
Balanced strength and stiffness in an SLA resin. Resists repeated loading and snapping — replaces injection-moulded ABS for functional prototypes.
Tensile Strength
46 MPa
Flex Modulus
2,200 MPa
Elongation
26 %
HDT
51 °C
Rigid 10K
10,000 MPa glass-filled ultra-stiff
The stiffest resin we run. Glass-filled Rigid 10K holds tight tolerances under load, ideal for jigs, fixtures, and precise tooling inserts.
Flex Strength
220 MPa
Flex Modulus
10,000 MPa
HDT
218 °C
Density
1.82 g/cm³
High Temp
238 °C heat deflection
Purpose-built for reflow ovens, autoclave tooling, and hot-air environments. Translucent amber appearance with minimal creep at elevated temperatures.
Tensile Strength
65 MPa
Flex Modulus
3,100 MPa
HDT
238 °C
Density
1.44 g/cm³
Durable
PE-like low-friction wear parts
Flexible, waxy surface finish with low friction coefficients. Best choice for sliding mechanisms, snap features, and parts that contact other surfaces in motion.
Tensile Strength
28 MPa
Flex Modulus
490 MPa
Elongation
55 %
HDT
36 °C
Requires high-temp chamber hardware. Contact us to qualify your project.
AdvancedPEEK
Polyetheretherketone
Metal replacement strength
Semi-crystalline thermoplastic with exceptional mechanical strength, chemical resistance, and heat resistance. Biocompatible — used in medical implants and aerospace.
AdvancedPEKK
Polyetherketoneketone
Wider processing window
Similar to PEEK but with a slower crystallisation rate, giving a more forgiving print window. Superior heat deflection for complex aerospace geometries.
AdvancedULTEM
Polyetherimide (PEI)
UL94 V-0 flame rated
Inherently flame retardant with excellent dimensional stability. More cost-effective than PEEK while still meeting aerospace interior requirements.
AdvancedPPSU
Polyphenylsulfone
Autoclave-sterilisable
Outstanding hydrolysis resistance and steam sterilisation capability. Perfect for medical device handles, plumbing components, and repeated sterilisation.
Comparison Table
| Material↓ | Process | Flex Str (MPa) | Modulus (MPa) | HDT (°C) | Moisture (%) | UV Resist | Cost Tier |
|---|---|---|---|---|---|---|---|
| ASA | FFF | 65 | 1,920 | 100 | 0.2 | ●●● | $ |
| High Temp | SLA | 68 | 3,200 | 238 | 0.2 | ●○○ | $$$ |
| Nylon 12 | FFF | 52 | 1,590 | 120 | 0.25 | ●○○ | $$ |
| Nylon 6 | FFF | 85 | 2,900 | 150 | 2.5 | ●○○ | $ |
| PA-CF | FFF | 151 | 5,460 | 186 | 1.2 | ●○○ | $$ |
| PC | FFF | 108 | 2,310 | 117 | 0.3 | ●●○ | $ |
| PC-CF | FFF | 131 | 5,320 | 205 | 0.25 | ●○○ | $$ |
| PEEK | ADV | 170 | 4,200 | 250 | 0.5 | ●●○ | $$$$ |
| PHAT-CF | FFF | 195 | 11,500 | 240 | 0.1 | ●○○ | $$$ |
| PPS-CF | FFF | 210 | 14,000 | 220 | 0.02 | ●●○ | $$$ |
| Rigid 10K | SLA | 220 | 10,000 | 238 | 0.15 | ●○○ | $$$ |
| Tough 2000 | SLA | 55 | 2,200 | 52 | 0.6 | ●○○ | $$ |
| ULTEM | ADV | 155 | 3,400 | 217 | 0.25 | ●●○ | $$$ |
Click column headers to sort. HDT = Heat Deflection Temperature at 0.45 MPa. UV: ●●● excellent, ●●○ good, ●○○ limited.
Choose FFF when…
- Part volume > 50 cm³ (cost advantage)
- Need carbon-fiber reinforcement (PA-CF / PC-CF / PPS-CF)
- Budget is the primary constraint
- Nylon toughness or flexibility required (PA6 / PA12)
- Chemical and fuel resistance needed (PPS-CF, PA12)
Choose SLA when…
- Tolerances < ±0.1 mm critical
- Optical clarity or fine surface finish required
- Gear teeth, threads, or thin features
- Extreme heat required (High Temp: 238 °C HDT)
- Tooling jigs needing ultra-stiffness (Rigid 10K)
Choose Advanced (PEEK/ULTEM) when…
- Biocompatibility or sterilisation required
- Metal replacement at > 200 °C sustained
- Aerospace certification demanded
- Chemical immersion in aggressive solvents
- When price is secondary to performance
Not sure which material fits your application?
Request a Material ConsultationOur fabrication fleet
Industrial-grade machines running 24/7. Each platform paired to the material family it does best.
Bambu Lab H2C
Multi-material with Vortek hotend switching system
Build Volume
330 × 320 × 325 mm
Max Nozzle Temp
350 °C
Max Bed Temp
120 °C
Chamber Temp
65 °C
Hotends
Vortek™ · 6 contactless
Multi-material
Up to 6 filaments
Materials
Bambu Lab H2S
High-speed single-nozzle · 30% faster than X1C
Build Volume
340 × 320 × 340 mm
Max Nozzle Temp
350 °C
Chamber Temp
65 °C
Print Speed
Up to 1000 mm/s
Acceleration
20,000 mm/s²
vs X1C
120% larger · 30% faster
Materials
VisionMiner 22 IDEX v4
PEEK, ULTEM & ultra-high-temperature engineering polymers
Max Nozzle Temp
500 °C
Chamber Temp
100 °C+
Max Bed Temp
200 °C
Extruders
IDEX Dual (independent)
Polymers
PEEK · ULTEM · PPSU · PPS
Specialty
High-temp composites
Materials
Formlabs Form 4
Precision tooling, jigs, and fine-feature functional parts
Build Volume
200 × 125 × 210 mm
Pixel Size
50 μm
Layer Height
25 – 300 μm
Technology
LFD™ · 60 LEDs
Throughput
< 2 hr typical prints
Reliability
99% print success
Materials
Formlabs Form 4L
Large-format SLA for full-scale jigs, enclosures & assemblies
Build Volume
353 × 196 × 350 mm
Pixel Size
46 μm
Layer Height
25 – 300 μm
Technology
LFD™ · 145 LEDs
Volume
24.2 L build capacity
Post-cure
Form Wash L + Cure L
Materials
Built for real workflows
Application-led manufacturing programs for teams shipping robotics, industrial systems, and mission-critical hardware.
Robotics & AutomationRobotics & Automation Teams
- End effectors and tooling in PA-CF / PC-CF
- Structural frames with topology optimization
- Sensor integration hardware and mounts
- Short-run production 10–1,000 units
Energy & IndustrialEnergy & Industrial Programs
- High-temp components in PPS-CF, PEEK, ULTEM
- Chemical-resistant housings and valve bodies
- Downhole and pressure-rated structural parts
- Certified material documentation for programs
Government & DefenseGovernment & Defense Contractors
- Mission-critical structural polymer parts
- High-performance composites for harsh environments
- First article inspection and supply agreements
- Production programs from prototype to scale
The future of manufacturing
is already here.
We close the loop between simulation and fabrication. Machine learning, robotics middleware, and physics-accurate virtual environments mean parts are validated before they exist — and optimized beyond what human intuition alone can achieve.
Simulate
Digital twin in Isaac Sim + MuJoCo
Optimize
ML-driven topology & parameter tuning
Generate
DfAM geometry from simulation data
Finished high-performance part
Adaptive Intelligence
Neural networks trained on print telemetry tune parameters in real time — predicting layer adhesion failures, compensating for thermal drift, and continuously improving part quality without human intervention.
- Defect prediction before failure occurs
- Process parameter auto-optimization
- Quality control from layer-by-layer data
Robot-Native Manufacturing
ROS 2 middleware connects our fabrication fleet into a coordinated production network. Part handoffs, in-process inspection, and post-processing are orchestrated autonomously across machines and workstations.
- Multi-machine fleet coordination
- Real-time process telemetry pipeline
- Hardware-agnostic integration layer
Physics-Accurate Simulation
NVIDIA Isaac Sim provides a photorealistic, physically accurate digital twin of the fabrication environment. We validate toolpaths, robotic motions, and thermal profiles in simulation before a single gram of material is consumed.
- RTX-accelerated physics simulation
- Synthetic training data generation
- Virtual commissioning of new geometries
Generative Design Validation
MuJoCo's contact-rich physics engine validates topology-optimized and generatively designed geometries under realistic loading conditions. Parts that survive the simulation are ready for print — zero physical prototyping waste.
- Contact dynamics & stress validation
- RL-driven topology optimization loops
- Sim-to-real transfer with <2% error
Simulation-validated. Physics-optimized. Ready to print.
Discuss a Sim-to-Part ProgramBuilt by engineers,
for engineers
Builders Generation is an advanced additive manufacturing partner for hardware companies, energy programs, robotics teams, and government contractors. We exist because production-grade additive manufacturing requires more than a machine — it requires material expertise, process control, and engineering judgment.
We run the full stack: generative design and topology optimization, composite and high-temperature FFF, precision SLA, and serialized production with full material documentation. Whether you need one prototype or ten thousand parts, the standard is the same — engineered to perform, built to last.
Engineering-first team
Design, materials, and production capability under one roof.
DfAM Native
Generative design to print-ready geometry
Full Stack
Design → Optimize → Manufacture → Ship
Engineering Materials
PEEK, PPS-CF, Rigid 10K — not PLA
Production Ready
FAI, certs, and supply agreements
Start a project
Tell us what you're building and we'll get back within one business day.