Most 3D printing filament sold in the US is manufactured overseas and shipped across the Pacific. Forgely is different. We make our filament right here in Roy, Utah — from raw pellets to finished spools.
Why Manufacture in Utah?
Utah's environment is actually ideal for filament production:
- Low humidity — moisture is filament's #1 enemy during extrusion. Utah's dry climate gives us a natural advantage.
- Central US location — faster shipping to both coasts compared to coastal manufacturing
- Skilled workforce — Utah's maker and engineering community is strong
- Vertical integration — manufacturing next to our retail store means instant quality feedback
The Extrusion Process
Here's how a spool of Forgely filament goes from raw material to your printer:
1. Raw Material Selection
We start with premium PLA pellets (also called resin). We source from suppliers who provide consistent molecular weight and low moisture content. Color masterbatch is added for our 30+ color options.
2. Drying
Even premium pellets carry some moisture. We dry all material to under 200 PPM moisture content before extrusion. This step is critical — wet pellets cause bubbles and inconsistent diameter.
3. Extrusion
Pellets are fed into our extruder, which melts them at precise temperatures (180–210°C depending on formulation). The molten plastic is pushed through a precision die to form a continuous strand of filament.
4. Diameter Control
This is where quality shows. Our laser diameter measurement system checks the filament diameter multiple times per second. We hold ±0.02mm tolerance — tighter than most manufacturers. Consistent diameter = consistent prints.
5. Cooling
The extruded filament passes through a water cooling bath at controlled temperature. Too fast and you get internal stress. Too slow and the filament deforms. We've dialed in the perfect balance.
6. Spooling
Clean, measured filament is wound onto 1kg spools with consistent tension. No tangles, no crossed layers, no surprises.
7. Quality Check
Every spool is weighed, visually inspected, and a sample length is measured for diameter consistency. If it doesn't meet spec, it doesn't ship.
Why It Matters for You
- Consistency — tight tolerances mean fewer failed prints and better surface quality
- Freshness — our filament goes from extrusion to shelf in days, not months on a container ship
- Support — if you have an issue, you're talking to the people who made it
- Community — your purchase supports Utah manufacturing and local jobs
See It in Action
Visit Forgely Roy and ask about our manufacturing process. We love showing people how their filament is made. You can see our filament on the shelf and know it was extruded just down the road.
Address: 5519 S 1900 W, Roy, UT 84067
Hours: Mon–Fri 11–6, Sat 11–3