Xenia Materials Launches Reinforced LSAM Materials for Large-Format Tooling

Updated on May 28, 2026 • 3 min read

Xenia Materials has introduced a new portfolio of reinforced pellet-based materials engineered for large-scale additive manufacturing tooling applications.

The range targets manufacturers seeking lightweight, durable and heat-resistant alternatives to traditional tooling production methods.

Designed for pellet extrusion 3D printing

The materials are developed for pellet extrusion LSAM systems and can be used to produce:

• jigs
• lamination masters
• thermoforming molds
• trimming fixtures
• master models
• structural tooling components

The portfolio is designed to support service temperatures from room temperature up to 260°C, depending on polymer matrix.

Why this matters for tooling

Large-format tooling often requires:

• dimensional stability
• low thermal expansion
• high stiffness
• autoclave compatibility
• resistance to thermal distortion

Xenia’s reinforced compounds use carbon fiber or glass fiber reinforcement to improve structural stability and reduce deformation during printing and use.

Material range

The portfolio includes:

• PETG-CF/GF for versatile large-format tooling
• ABS-CF for prototypes, trimming jigs and industrial fixtures
• PC-CF for tooling up to around 140°C
• PC-HT-CF for demanding automotive and aerospace tooling
• PEI-CF for high-temperature aerospace and defense tools
• PESU-CF for flame retardant and chemically resistant tooling
• PEEK-CF for high-end metal-replacement applications
• PEKK-CF for continuous high-temperature use and easier processing than PEEK

Target industries

The materials are aimed at:

• aerospace
• automotive
• motorsport
• defense
• marine
• construction
• energy
• transport

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This article is developed based on real engineering experience, machine testing data, and practical production knowledge from Jota Machinery’s work in advanced composite manufacturing.

All technical explanations—including material structure, processing methods, and performance characteristics—are reviewed and verified by our engineering team to ensure accuracy and real-world relevance.

To improve clarity and structure, AI-assisted tools may have been used during content organization and language refinement. However:

• All key technical insights originate from first-hand industrial experience
• All data and claims are manually reviewed and validated
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Editorial Perspective

Xenia’s launch reflects the growing importance of pellet-based LSAM in tooling production.

As manufacturers push for faster tooling, lower cost and shorter development cycles, reinforced thermoplastic compounds are becoming a practical alternative to metal, epoxy board and traditionally machined tools.

The key value is not only faster printing. It is the ability to produce large, stable, heat-resistant tooling with reduced weight and improved design flexibility.