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- Install, operator training, and validated print profiles for your starting materials
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3D printers, Business 3D Printers, Composite Tooling, Engineering 3D Printers, FGF 3D Printers, Jigs&Fixtures 3D Printers, Large Format 3D Printers, Manufacturing 3D Printers, Pellet, Plastic 3D printers · FGF
Kings FGF2435 Hybrid 5-Axis Pellet 3D Printer – Flagship Large Format | 3500×2400×1000 mm
Flagship hybrid additive + subtractive pellet 3D printer — 138×94×39 in / 3500×2400×1000 mm bed with integrated 5-axis CNC milling, raw polymer granules, 3–16 mm nozzles, up to 30 kg/h. Optional 450°C nozzle. Material cost 5–10× lower than filament.
- ✓ Print + 5-axis finish-machine in one setup — no crane move to a separate mill
- ✓ 138×94×39 in / 3.5×2.4×1.0 m bed — the largest one-piece molds Kings builds
- ✓ Lead time: 2–3 months — configured to order, installed and trained on-site
$586,000
Price held 7 days after order.
Install + training included
Tailored service plan
Built for production teams
What your production engineering lead actually checks
Print and finish-machine in one setup
Integrated 5-axis CNC means contoured mold faces get machined on the same bed — tolerances a printed-only or 3-axis part can't hold, without craning a multi-ton part to a separate mill.
Print a benchmark part first
Send your STL and target material — we print a test part on our own FGF in California, so you see the surface, strength, and scale before you commit to the system.
An applications engineer on the line
Factory-trained engineers who run large-format AM daily — drying protocols, screw profiles, print and 5-axis machining parameters. Sub-4h reply, NDA standard. Use the Talk to applications engineer button above.
3500×2400×1000 mm
Build volume
Additive + 5-axis CNC
Configuration
3–16 mm
Interchangeable nozzles
Up to 30 kg/h
Extrusion output
About this product
Kings FGF2435 is Kings’ flagship hybrid additive + subtractive platform — a 138×94×39 in / 3500×2400×1000 mm bed with an integrated 5-axis CNC milling head. It prints full-scale molds and patterns from raw polymer granules at up to 30 kg/h, then finish-machines complex surfaces in the same setup — no crane move to a separate mill. Pellet feedstock keeps material cost 5–10× below filament, and a 3–16 mm nozzle range plus 450°C option cover structural fill through engineering compounds on parts measured in meters.
Why engineers choose the FGF2435
Four things production teams verify before committing to flagship hybrid FGF.
Integrated 5-axis CNC
Print near-net, then finish-machine contoured and undercut surfaces on the same bed — machined tolerances on molds a 3-axis mill can’t reach.
Pellet economics
Granulate 5–10× below filament cost for the same polymer — injection-molding feedstock off the open market, no vendor lock-in.
3.5 m bed, up to 30 kg/h
138×94×39 in / 3500×2400×1000 mm — the largest one-piece molds, marine plugs, and full-scale patterns Kings builds.
450°C, 24/7 auto-feed
Four-zone heating, a 100 kg hopper, and 24/7 auto-feed run engineering compounds — PA+CF, PC+CF, PEI+CF — for multi-day production.
How we deliver it
Every FGF2435 ships as a working process, not a crate — configured, installed, and validated.
Step 01
Configured to the application
Nozzle set, 5-axis machining strategy, and material plan specced with an applications engineer before the order ships.
Step 02
Installed and trained on-site
US-based installation, three-phase power and air hook-up, and operator training from California — your team runs the first build with our engineer.
Step 03
Validated print + mill profiles
Print and 5-axis machining profiles for your starting materials plus a granulate drying workflow, verified on your machine before hand-off.
Materials
- Standard (up to 350°C): ABS, ABS-FR, ABS+CF, ABS+GF, PETG, PETG-FR, PETG+GF, PLA, ASA, ASA+GF, TPU, PC, PA, PP, PA+CF, PC+CF
- High-temperature option (up to 450°C): PEI+CF and other engineering compounds
- Pellet size accepted: 0.04–0.2 in / 1–5 mm — standard injection-molding granulate and most regrind
Pellet economics, in numbers
The 5–10× claim, shown on one real part instead of adjectives.
| ABS example | Pellets (FGF2435) | Filament (FFF) |
|---|---|---|
| Material price, typical 2026 market | ~$4 / kg | ~$22 / kg |
| 220 lb / 100 kg full-scale marine mold — material cost | ~$400 | ~$2,200 |
| Saving on that one part | ~$1,800 — about 5.5× lower material cost | |
Typical open-market pricing for standard ABS granulate vs. ABS filament; filled and engineering grades scale similarly. Your exact numbers depend on material and supplier — ask us for a cost-per-part calculation on your geometry.
Technical specifications
- Build volume: 138×94×39 in / 3500×2400×1000 mm
- Configuration: hybrid additive + subtractive with integrated 5-axis CNC milling
- Max extrusion output: up to 30 kg/h
- Nozzle diameter: 0.12–0.63 in / 3–16 mm
- Max nozzle temp: 350°C standard; 450°C optional high-temp nozzle
- Nozzle heating: four-zone intelligent heating
- Bed / working surface temp: up to 120°C (magnetic platform / tempered glass)
- Hopper: 100 kg with integrated 24/7 pneumatic auto-feed
- Chamber heating: optional
- Power: three-phase 380 VAC, up to ~70 kW rated
- Compressed air: 0.6 MPa
- Machine dimensions: 286×154×173 in / 7277×3906×4383 mm; weight 24,251 lb / 11,000 kg
High-temperature nozzle package, chamber heating, and the granulate dryer are priced per configuration — request a quote for a full budget. Leasing and financing available.
Typical applications
Where production teams run the FGF2435 today.
Marine molds
Full-scale hull plugs and deck tools
Aerospace tooling
Large layup and trim fixtures
Automotive
Full-scale bucks and master models
Composite tooling
Layup molds, machined sealing faces
Foundry patterns
Large sand-casting patterns, machined
Energy & wind
Blade molds and large fixtures
Case snapshot · representative project
A 3 m marine hull plug printed in one piece on the FGF2435 in ABS+GF, then the parting surface finish-machined on the same 5-axis bed — replacing a bonded, hand-faired plug that took weeks of loft work. Send your STL and we’ll run the same math on your part.
Not sure the FGF2435 is the right fit?
Three reasons teams pick a different FGF platform — tap the closest match and we’ll help you qualify it.
Smaller hybrid bedKings FGF2400View printer →Additive only, single-phaseKings FGF1800View printer →Robotic production cellHeron AM HFView printer →
Tell us your part size, target material, and whether you need 5-axis machined surfaces — our applications engineer will recommend the right platform and configuration on a spec call.
Why source through Additive Plus
- Official Kings 3D US representative — US sales, service, spares, and application engineering, direct from California.
- FGF process expertise — drying protocols, screw profiles, and print + 5-axis machining parameters by material family; no ramp-up trial-and-error.
- In-house large-format printing — validate geometry and material before system commitment.
- US-based support — installation, training, and field service from California.
- Leasing and financing available; sub-24h engineer response.
| Build Volume | 138x94x39 in / 3500x2400x1000 mm |
| Technology | FGF |
| Brand | Kings3D |
| Printing Materials | Plastic Pellets |
| Max Part Size | 138x94x39 in |
| Machine model | FGF-2435 |
| Molding technology | Fused granular fabrication |
| Configuration | Hybrid additive + subtractive, integrated 5-axis CNC milling |
| Max extrusion output | Up to 30 kg/h |
| Optional nozzle diameter | 0.12–0.63 in / 3–16 mm |
| Max nozzle temperature | ≤350°C (450°C optional high-temp nozzle) |
| Nozzle heating method | Four-zone intelligent heating |
| Working surface temperature | ≤120°C |
| Workbench contact surface | Magnetic platform / tempered glass |
| Materials | PLA, ABS, ABS-FR, ABS+GF, ABS+CF, PETG, PETG-FR, PETG+GF, ASA, ASA+GF, TPU, PC, PA, PP, PA+CF, PC+CF, PEI+CF |
| Material particle diameter | 0.039–0.197 in / 1–5 mm |
| Storage hopper | 220 lb / 100 kg, integrated 24/7 pneumatic auto-feed |
| Chamber heating | Optional |
| Drive mode | Servo motor |
| Rated power consumption | 70 kW |
| Power supply voltage | Three-phase AC 380V |
| Compressed air pressure | 0.6 MPa |
| Machine dimensions | 286×154×173 in / 7277×3906×4383 mm |
| Machine weight | 24,251 lb / 11,000 kg |
| Printing connection method | SD / USB / WiFi |
| Slicing supported formats | STL / OBJ / AMF / 3MF / STP / STEP |
Product videos
Want proof before you commit?
Send us your STL and we'll print a paid benchmark part on a Kings FGF machine in California — your geometry, your material, in your hands before you buy the system. You get the part, a cost-per-part figure, and the validated print profile.
Other products teams run alongside Kings FGF2435 Hybrid 5-Axis Pellet 3D Printer – Flagship Large Format | 3500×2400×1000 mm
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Large-format industrial SLA. Marble frame. Vacuum recoating. Built for automotive panels, one-piece patterns, dental models, and architectural forms — without stitching or Z-seam artifacts.
- ✓ 1000 × 1000 × 600 mm build chamber — a full bumper fascia or a batch of shoe lasts in one run
- ✓ Solid-state 355 nm Nd:YVO4 laser · 0.075–0.8 mm variable beam · 15.0 m/s max scan
- ✓ Full-marble machine frame — thermal stability for ±0.1 mm part accuracy
- ✓ Lead time: 2–3 months — on-site install, calibration & operator training included
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- Built for small series — repeatable ceramic parts, not one-off prototypes.
- Print from 60 mL — 10 mL with SAM option · change ceramic in ~20 min.
- Lead time: configured to order — install, training & scale-up support from California.
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- Fully enclosed 256×256×256 mm — engineering filaments without warping
- AMS multi-color — up to 16 colors with chained units
- 500 mm/s with vibration compensation — fast and accurate
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The highest-throughput system in the 403 class: two 300 W fiber lasers scanning in parallel push build rates up to 9 L/h on a 15.7×15.7×17.7 in / 400×400×450 mm build (up to 540 mm tall). Built for serious polymer production, running high-performance nylons and TPU with fully open parameters. Sold, installed and supported in the US by Additive Plus.
- Dual 300 W fiber lasers — up to 9 L/h, the fastest 403-class throughput.
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Large-format pellet extrusion 3D printer — 31×24×31 in / 800×600×800 mm, raw polymer granules, 0.4–2 mm nozzle selection. Optional 450°C nozzle for PEEK/PEKK/ULTEM. Material cost 5–10× lower than equivalent filament.
- ✓ Pellet feedstock — 5–10× lower material cost vs. filament at the same polymer
- ✓ Optional 450°C nozzle — PEEK, PEKK, ULTEM at 800×600×800 mm scale
- ✓ Lead time: 2–3 months — configured to order, installed and trained on-site
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- Compact, production-grade — 120×120×100 mm build, 20 µm layers, 10+ alloys incl. dental CoCrMoW.
- Official US Farsoon dealer — installation, training, parameter & warranty support by Additive Plus.
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Prints 316L, 420, AlSi10Mg, Maraging Steel Grade 300, ST1
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From production teams running large-format FGF
Unedited feedback from engineers running pellet 3D printing
★★★★★
We moved our thermoforming tooling from outsourced CNC to large-format FGF. A big ABS+GF mold prints overnight and costs a fraction of machined aluminum.
MR
Mark Production Engineering Lead · Packaging manufacturer
★★★★★
Pellet feedstock was the whole point — we run the same PA+CF granulate as our injection molding line. No filament markup, no vendor lock-in.
ES
Elena Materials Engineer · Automotive supplier
★★★★★
Support is the difference. Their engineer dialed in drying and screw settings for our recycled compound in the first week.
DK
David R&D Manager · Consumer products
Common questions
Don't see yours? Email [email protected] — NDA standard, typical reply within 4 hours.
What does hybrid additive + subtractive with 5-axis CNC mean on the Kings FGF2435?
The Kings FGF2435 prints a part from polymer pellets and then finish-machines it with an integrated 5-axis CNC head on the same bed. Five axes let the mill reach contoured, undercut, and draft surfaces a 3-axis head cannot, so you get machined tolerances and finish on complex molds without craning a multi-ton printed part to a separate machining center. It is Kings' flagship configuration for full-scale tooling.
What is the difference between FGF pellet printing and filament (FFF) printing?
The Kings FGF2435 prints directly from plastic pellets — the same feedstock used in injection molding — instead of filament. Pellets cost a fraction of filament for the same base polymer and open access to grades never extruded into filament, including glass- and carbon-filled compounds. A 100 kg hopper with 24/7 auto-feed sustains multi-day builds at up to 30 kg/h. For full-scale molds and patterns, the Kings FGF2435 economics are hard to match with filament.
What pellets can the Kings FGF2435 process — can I run my own compound or regrind?
The Kings FGF2435 is an open-material system: PLA, ABS, ASA, PETG, TPU, PC, PA, and PP, including fire-retardant grades and filled compounds such as ABS+GF, ABS+CF, ASA+GF, PETG+GF, PA+CF, PC+CF, and PEI+CF with the high-temperature option. It accepts pellets 1–5 mm in diameter, which covers standard injection-molding granulate and most regrind. If you run a proprietary blend or recycled compound, our applications engineers will help you qualify it on the Kings FGF2435 before you commit.
How big a part can the FGF2435 build?
The Kings FGF2435 has a 138×94×39 in / 3500×2400×1000 mm bed — the largest in the Kings FGF line. It builds full-scale marine hull plugs, aerospace layup tooling, and automotive master models in one piece, with up to 30 kg/h of output and integrated 5-axis machining to finish them. For a smaller hybrid footprint, the Kings FGF2400 steps down to a 2.4 m bed.
Can the Kings FGF2435 print carbon-fiber or glass-fiber filled materials?
Yes. Fiber-filled compounds — ABS+GF, ABS+CF, ASA+GF, PETG+GF, PA+CF, PC+CF, and PEI+CF with the high-temperature option — are core applications for the Kings FGF2435. Fiber-filled pellets are widely available as injection-molding granulate, while the same compounds in filament are expensive or unavailable. Hardened wear components in the extrusion path handle abrasive fibers; our engineers recommend the right nozzle and 5-axis machining setup for your compound.
Do pellets need drying before printing?
Yes — the same moisture rules as filament apply, and hygroscopic polymers (PA, PC, PETG) must be dried to the resin maker's spec before printing on the Kings FGF2435. The 100 kg hopper with 24/7 pneumatic feeding is designed to work in line with a granulate dryer, the standard setup in injection-molding shops. We spec a drying workflow for your material as part of installation and training.
What surface finish can the FGF2435 achieve?
On printed-only surfaces, plan for visible layer lines — bead geometry depends on the 3–16 mm nozzle installed. The advantage of the Kings FGF2435 is the integrated 5-axis subtractive head: critical and contoured faces are CNC-milled on the same bed to a machined finish and tolerance, so you do not depend on print resolution for mold surfaces. Typical practice for tooling: print near-net shape fast, then 5-axis machine the working surfaces.
What infrastructure does the Kings FGF2435 require?
Three-phase 380 V AC power (up to ~70 kW rated), compressed air at 0.6 MPa, and floor space for an 11,000 kg machine measuring roughly 7277×3906×4383 mm with a 3500×2400×1000 mm build area. The working surface runs up to 120°C; chamber heating is optional for high-shrinkage engineering polymers. Connectivity is SD, USB, and WiFi with STL, OBJ, AMF, 3MF, STP, and STEP support. We confirm site and rigging requirements before shipment as part of every Kings FGF2435 installation.
Place your order, or talk to an engineer first
Order Kings FGF2435 Hybrid 5-Axis Pellet 3D Printer – Flagship Large Format | 3500×2400×1000 mm direct, or talk to materials engineer