AON3D Hylo™

650 x 450 x 450mm

Huge ULTEM™ and PEEK parts

More than twice the build area of a 22 IDEX, held at 250ºC. Ducts, housings, layup tools and fixtures come out in one piece instead of being cut up and bonded.

250ºC chamber

Thick sections that need to be strong

A 100ºC chamber is fine for thin walls. Thick ULTEM™ and PEEK sections need the whole part held near its processing temperature so layers deep inside fuse properly. Hylo's 250ºC chamber and Basis tuning do that, and the parts come out measurably stronger.

Sensors + Basis™

Flight and qualified parts

Print ULTEM™ 9085, which meets FAR 25.853 flame, smoke and toxicity requirements, then hand your quality team a sensor record of how every part was built. That's the paper trail flight and production parts need.

The old way

With Basis AI on Hylo

Physics plus machine learning

A full physics simulation of a print takes far too long to be useful. Basis pairs physics-based thermal models with machine learning, so it simulates the whole build much faster than the printer can print it.

Down to the bead

The simulation tracks temperature at points about a millimeter apart along every bead, including the effect of airflow in the chamber. It estimates how strong each layer weld will be before the part exists.

Your part, your material

Basis reads your G-code, looks at the actual features being printed, and adapts the settings to the exact brand and grade of filament you loaded. AON3D says it keeps improving as more Hylos run.

01

Simulate

AI-accelerated thermal simulation of the full build, from your part, your slicer settings and the polymer's physics. It also estimates layer weld strength.

02

Optimize

Basis writes dynamic speeds and temperatures, mm by mm, to stop regional defects and get maximum layer bonding without overheating.

03

Print

Hylo's self-calibration, material handling and process control run the job the same way every time.

04

Qualify

Sensor data builds a digital twin of the part. Basis checks it for hidden defects and gives you a record of how it was built.

Find defects you can't see

Hylo logs nozzle force, feed, thermals and motion for every layer. Basis compares that against the plan to flag cold welds, debris and dross inclusions, warping, cracking, and over- or under-extrusion inside the part. It's non-destructive inspection without cutting a part open.

Qualify parts faster

Every part ships with its build data. That cuts the downstream QC burden and gives you the evidence you need to qualify a printed part for production or flight.

Run the whole fleet

Manage printers, projects, users, revisions, material inventory and maintenance from one platform, then print qualified parts from a cloud-based digital inventory wherever you need them.

Ultra-performance

PEEK · PEKK · PAEK · ULTEM™ 9085 · ULTEM™ 1010 · TPI

High-performance

PPSU · PSU · PVDF

Engineering

PC · Nylon (PA6, PA6/66, PA12) · POM · PP · TPU · TPE

Commodity

ABS · ASA · PETG · PLA

Fills

Carbon fiber · glass fiber · Kevlar® · ESD-safe

Supports

Water-soluble · detergent-soluble · breakaway

How much does the Hylo cost?

Hylo is quoted by configuration, so we don't list a price here. Send us your parts and materials and we'll put together a formal quote your purchasing team can run a PO against. Financing is available.

Hylo or 22 IDEX -- which one do I need?

The 22 IDEX prints about 80% of the production PEEK and ULTEM™ parts that come through our print service, for $14,900. There's no hard size cutoff: a big thin-walled part or a small thick one usually prints fine. Once a part gets bigger than a softball with thick sections, or needs a flight-grade build record, you want Hylo's 250ºC chamber and Basis AI. Send us the part and we'll tell you straight.

Can Hylo make flight parts?

Hylo prints ULTEM™ 9085, which meets FAR 25.853 flame, smoke and toxicity requirements, and its sensors and Basis record how every part was built. Certifying a specific part is between you and your certifying authority. We'll help you set up a repeatable process that supports it.

What does the AI actually do?

Before the print, Basis combines physics models with machine learning to simulate how heat moves through your exact part, about every millimeter along each bead. Then it rewrites the G-code for your geometry and your specific material, region by region, so each layer bonds without overheating. During the print, Hylo's sensors feed a digital twin of the part that Basis checks for hidden defects like cold welds, debris inclusions and over- or under-extrusion.

Can I see one run before I buy?

Yes. Many Hylo owners across the US are happy to show theirs. Tell us where you are and we'll try to set up a demo near you, or walk you through it on a video call.

Does it need special power or air?

Yes. Plan for a 208-240VAC single-phase, 40A circuit and a clean, dry, oil-free air supply at 90-135 psig and 1.5 SCFM. The site planner above has the full list, and we can send you a compressor and dryer setup that meets AON3D's air spec.

Is it really an open material system?

Yes. Any 1.75mm filament, no RFID chips and no unlock fees. AON3D's validated profiles cover the common engineering polymers, and the process controls are open for custom materials.

Who handles warranty and support?

Hylo carries AON3D's factory warranty. We'll quote AON3D training and the Pro Success Plan with your system, and you can call us first for anything: 833-774-6863.