High-Temperature FDM 3D Printing Services
UK-based Model Making company
Over 50 years of expertise
Custom parts delivered in days
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High Temp Engineering-Grade Thermoplastics for Aerospace, Defence & Motorsport
When standard polymers are no longer capable of meeting performance requirements, Malcolm Nicholls Ltd delivers advanced high-temperature FDM 3D printing solutions using some of the industry’s most capable engineering-grade thermoplastics.
From PEEK, PEKK and ULTEM™ through to PPSU and carbon-fibre reinforced materials, we help engineers, manufacturers and product developers produce lightweight, high-strength parts designed to perform in the most demanding environments. Our industrial FDM capability supports everything from rapid prototyping and functional testing through to low-volume manufacturing and end-use production.
With over 50 years of manufacturing expertise, Malcolm Nicholls Ltd supports clients across aerospace, defence, motorsport, automotive, medical and industrial engineering sectors, delivering precision components with exceptional thermal, mechanical and chemical performance.
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What is High-Temperature FDM?
High-temperature FDM (Fused Deposition Modelling) is an advanced additive manufacturing process that selectively deposits molten thermoplastic material layer by layer to manufacture functional engineering components. Unlike conventional FDM materials such as PLA or ABS, high-performance polymers require specialist equipment capable of maintaining elevated chamber and extrusion temperatures throughout the build process.
The result is a manufacturing solution capable of producing components with:
- Exceptional heat resistance
- High strength-to-weight ratios
- Outstanding chemical resistance
- Excellent fatigue performance
- Minimal off-gassing
- Flame, smoke and toxicity (FST) compliance
- Electrical insulation properties
- Long-term dimensional stability
For many applications, these advanced polymers can replace traditionally machined metal components whilst reducing weight and improving design flexibility
Why Malcolm Nicholls?
UK Based
With headquarters in the Midlands, we can deliver your 3D parts nationally.
Years of Expertise
We are a family run business with decades of experience.
Finished to Perfection
A team of traditional model makers in house to give your 3D Printed Model the wow factor.
More Than Just Batch Manufacturing
With our suite of machines and 3D printing technology we also specialise in low-volume manufacturing, Vacuum Casting, CNC Machining and more.
Industrial 3D Printing Technologies
Learn more about the different options we offer
SLA
Our SLA technology delivers exceptional surface finishes, tight dimensional tolerances and outstanding detail reproduction.
Ideal for:
- High-fidelity prototypes
- Master patterns for vacuum casting
- Appearance models
- Large-format components
- Production tooling
With build volumes up to 800mm, our large-format SLA systems support both oversized components and high-density batch production.
SLS
SLS is one of the most widely adopted additive manufacturing technologies for production applications. Using a powder bed fusion process, nylon powder is selectively fused layer by layer to create strong, functional components without support structures.
Applications include:
- End-use parts
- Production-grade polymer components
- Automotive components
- Aerospace applications
- Functional testing
- Batch manufacturing
FDM
Manufacturing FDM known as fused deposition modelling is the most widely available form of 3d printing. It is an additive manufacturing technology that selectively deposits molten plastic to build parts layer by layer.
Fused Deposition Modelling enables the manufacture of durable engineering components using advanced thermoplastics.
Suitable for:
- Jigs and fixtures
- Manufacturing aids
- Functional prototypes
- Structural components
- High-temperature applications
Why Choose High-Temperature FDM?
Reduce Weight Without Compromising Performance
High-performance thermoplastics such as PEEK and PEKK offer exceptional mechanical properties whilst being significantly lighter than aluminium and steel alternatives.
This makes them particularly valuable in industries where weight reduction directly impacts performance, fuel efficiency and operational costs.
Eliminate Tooling Costs
Produce functional end-use parts without the investment associated with injection mould tooling. This makes high-temperature FDM ideal for:
- Low-volume manufacturing
- Bridge production
- Replacement parts
- Legacy components
- Bespoke engineering projects
- Rapid product development
Accelerate Product Development
Move from CAD model to physical component in days rather than weeks, enabling rapid design validation, field testing and programme development.
Design Freedom
Manufacture complex geometries, internal features, lightweight structures and consolidated assemblies that would be costly or impossible using traditional manufacturing methods.
High-Performance Materials
At Malcolm Nicholls Ltd, we manufacture components using advanced engineering thermoplastics including PEEK, PEKK, ULTEM™ 9085 and ULTEM™ 1010, enabling the production of lightweight, high-strength parts for aerospace, defence, motorsport, medical and industrial applications. These high-performance materials offer exceptional thermal stability, chemical resistance, mechanical strength and flame-retardant properties, making them ideal for demanding environments where traditional polymers cannot perform.
PEEK & PEKK
Often considered the pinnacle of polymer additive manufacturing, PEEK and PEKK deliver metal-like performance with significantly reduced weight. With excellent strength-to-weight ratios, continuous high-temperature performance, chemical resistance and durability, they are widely used for aerospace components, defence systems, motorsport applications, composite tooling and high-performance engineering assemblies. Their ability to replace machined metal parts makes them particularly valuable where weight reduction and performance are critical.
ULTEM™ 9085
A trusted material across aerospace, rail and transportation sectors, ULTEM™ 9085 combines low weight with excellent mechanical properties and FST (Flame, Smoke and Toxicity) compliance. It is commonly used for aircraft interiors, vehicle systems, production tooling and functional end-use components.
ULTEM™ 1010
Offering some of the highest heat resistance available within FDM manufacturing, ULTEM™ 1010 is ideal for aerospace tooling, composite lay-up tools, manufacturing fixtures and high-temperature functional testing. Its combination of strength, thermal stability and chemical resistance makes it a popular choice for advanced engineering applications.
Aerospace, Defence & Motorsport Applications
Our high-temperature FDM materials are trusted across aerospace, defence and motorsport industries where performance cannot be compromised. From lightweight aircraft brackets and UAV components to defence equipment housings, composite tooling, aerodynamic development parts and race vehicle components, these advanced polymers help engineers reduce weight, improve performance and accelerate product development without the costs associated with traditional manufacturing methods.
Professional 3D Printing On Demand
As the UK’s leading 3D printing company, we have an extensive range of 3D printing services including.
Large Format
Large format 3D printing service, utilising our large format SLA 3D printers with their impressive build platforms of 800 x 800 x 600mm.
Transparent
We can produce large transparent 3D printing without the need for sectioning and fabricating back together, by utilising our large format SLA 3D printers.
Carbon
Carbon has proven itself for its reliability in the toughest of environments, whether your looking to use it in low volume production or rapid prototyping Carbon 3D Printing is a great option.
Securing Your 3D Printing Project with an NDA
We understand the sensitivity of your projects and operate with the utmost confidentiality. Strict adherence to non-disclosure agreements (NDAs) is ingrained in our company culture. We’re happy to work within your NDA framework and are prepared to sign mutual agreements to ensure your intellectual property remains safeguarded. Trust and transparency are cornerstones of our business, and we’re committed to partnering with you with complete peace of mind.