Z-Polymers Tullomer Fiber Brings Six Times the Strength of Steel to 3D Printing

A New High-Performance Fiber Enters the 3D Printing Market

Boston-based Z-Polymers has started selling Tullomer, a liquid crystal polymer fiber that the company claims is the first new high-performance fiber in more than 20 years. Tullomer is one-sixth the weight of steel and up to six times stronger than comparable materials. It produces minimal outgassing, has a limiting oxygen index above 40, and chars without burning. The company says it can be processed on standard desktop 3D printers.

The fiber is melt-spun from liquid crystal polymer, avoiding the solvent-based production methods used by aramid fiber makers. Z-Polymers says Tullomer outperforms PEEK by more than four times on mechanical strength while maintaining competitive pricing. The material is recyclable, PFAS-free, and has a low-carbon footprint. It is available as pellets, filament, monofilament, and multifilament yarn.

For 3D printing, Z-Polymers offers Tullomer in filament form. The company recommends incorporating 10% to 20% Tullomer into existing filament bases to boost strength beyond PEEK and ULTEM levels. Composite filaments are coming soon. The material prints at nozzle temperatures between 290C and 350C, with a bed temperature of at least 120C. Cooling is not recommended for optimal strength.

Aerospace is the primary target market. Tullomer's low outgassing makes it suitable for satellites and space hardware, where evaporated materials can interfere with sensitive electronics. The material is already being tested in drones, where its RF transparency solves a problem that carbon fiber creates: carbon fiber can block antenna signals, while Tullomer does not. The company is also pursuing medical device applications, including sutures and catheters, because the material shows no cytotoxicity.

Z-Polymers is part of the AFFOA Product Accelerator program and has partnerships with textile manufacturers for domestic scale-up. The fiber is manufactured in the US and is subject to export control regulations. Whether Tullomer gains widespread adoption depends on how well it performs in real-world structural applications and whether the price stays competitive with established high-performance fibers like carbon fiber and PEEK.