4D Fusion Services

Custom Polymer based Composite Prototyping & Testing

Bring your composite material designs to life with our 4D Fusion technology. Thanks to 4D Fusion technology encapsulated in a single production process, we can rapidly accelerate the prototyping process and validate material performance.

4D Fusion Technology

3D & 4D Additive Manufacturing

Combining 3D and 4D additive manufacturing methods for rapid prototyping in one production unit developed, produced and patented by 4D Fusion.
Short Time to Tested Recipe

Quickly develop material inserts and print samples, reducing time from concept to testing.
Minimal Material Requirements

Develop samples with minimal material usage, reducing waste and cost.
Reduced Risk & Cost

Minimize risk and cost with rapid prototyping and iterative testing.

Custom Material Prototyping

We create prototype unique composite formulations with precise mechanical, thermal, and chemical properties.
Functional Add-ons

Integrating advanced components like nanomaterials, bio-based fibers, and rare-earth metals to enhance material properties.
Commercial Base Materials

Utilizing readily available or unique base materials to achieve cost-effective serial production.

Process description

Our 4D Fusion system offers versatile prototyping methods.

  • Custom Composite Sample Production

    • 4D Fusion system inserts preparation in different variations of saturation and gradation of additives,
    • Advanced 3D and 4D additive manufacturing technologies for accurately creating composite prototypes using your unique material formulations.
    • Flexible manufacturing processes that accommodate a wide range of composite types, functional materials and smart materials including nanocomposites, and hybrid materials.
    • Prototyping using one of available 4D Fusion techniques: classical 2,5D print, pouring, foaming, smearing or sedimentation.

  • Comprehensive Testing & Validation

    • Comprehensive testing, including mechanical, thermal, and environmental assessments, ensures compliance with required standards. We cooperate in materials testing with Military University of Technology, Silesian University of Technology, and Institute of Non-Ferrous Metals in Gliwice.
    • We provide iterative refinement based on test results to optimize material properties.
    • Data-driven analysis and reporting to provide actionable insights on material behavior, strength, and failure modes.

  • Iterative Prototyping

    • Support for multiple rounds of prototyping to refine and optimize your composite design based on test results.
    • Rapid turnaround times to keep your development process on track and responsive to changes in design or performance requirements.
    • Collaboration with your team to make adjustments in real-time, ensuring the final prototype aligns with your goals.

  • Process Optimization

    • Tailoring of manufacturing processes to improve prototype quality and scalability for mass production.
    • Integration of feedback from testing into the manufacturing process to enhance material consistency and reduce defects.
    • Consultation on potential process improvements or alternative approaches to achieve better material performance.

  • Quality Assurance & Compliance

    • Adherence to industry standards and regulations throughout the prototyping and testing process.
    • Detailed documentation and certification to support compliance with relevant safety and quality standards.
    • Environmental impact assessments to ensure that prototypes meet sustainability goals.

Custom Composite Sample Production

Pouring

The pouring technique enables us to create complex shapes and intricate designs by precisely pouring the composite material into FDM printed shapes.

Foaming

This process incorporates gas into the composite material to create a lightweight and porous structure, enhancing its insulation or sound absorption properties.

Smearing

By precisely smearing the material across a surface, we can achieve high uniformity and better surface textures.

Sedimentation

This method allows for the creation of solid composites with varied properties by precisely depositing each layer of material.

Material Testing and Validation

Testing based on customer applications planned
Tensile strength, impact resistance, fatigue life
Heat resistance, thermal conductivity, thermal expansion
Weather resistance, chemical resistance, UV exposure
Our material testing and validation services are customized to your specific needs and industry standards, ensuring reliable results.
We ensure our materials meet the highest standards through comprehensive testing and validation with our partners from Polish Universities, the Military University of Technology and the Silesian University of Technology.

Material and know-how transfer to your production process

We are open to transferring our know-how and technology into the production line by developing scalable processes to transition from lab-scale production to full-scale manufacturing. We support our customers with process development by:

  • Tailoring 4D Fusion manufacturing processes for serial cost effective composite production.

  • Tailoring serial production lines based on extrusion, pultrusion, or additive manufacturing for composite production.

  • Optimization of material processing to reduce costs, minimize waste, and improve sustainability.

Why 4D Fusion

We work closely with our clients to identify specific needs and develop tailored solutions.

Expertise

Our team consists of leading scientists and engineers with deep experience in composite material science.

Innovation

We stay ahead of industry trends, utilizing the latest technologies and materials to create next-generation composites.

Customization

We tailor every project to your specific needs, ensuring that the final product exceeds expectations.

Sustainability

We are committed to develop materials with minimum carbon footprint, waste production and environmental pollution. We develop not only high-performing but also environmentally responsible

Sustainability and Compliance

We are committed to developing environmentally responsible products.

Carbon Neutral

We save time, energy and resources to absolute minimum required. We develop not only high-performing but also environmentally responsible.

Waste reduction

Our materials development and prototyping process necessitates a minimal amount of input materials, reducing the waste required by other methods.

Lifecycle Analysis

We offer a comprehensive analysis of the environmental impact of materials and processes.

Industries Served

We provide tailored composite solutions for various industries.

Aerospace and Automotive

Lightweight and high-strength composites for aircraft and spacecraft for incoming space challenge

Electrochemistry

4D printed Sensors eg. Ion Selective Electrodes

Construction

Sustainable and high-performance composites for building materials.

Renewable Energy

High performance composites for joint fight against climate change.

Contact Us

 

Have a question or need help?
We’re here for you!

 

You can reach us via email: info@4dfusion.eu
or telephone: +48 577 711 688

Company Details:

4D Fusion
43-155 Bieruń
ul. Węglowa 14

NIP: 6463012362
KRS 0001101668
REGON: 528426894
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