FUSED DEPOSITION MODELING (FDM)
- FDM technology can go about building quick prototypes with strength and speed, at a very economical price in a wide range of thermoplastic materials, which makes it a very attractive option.
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OVERVIEW
APPLICATIONS
MATERIALS
DESIGN RULES
POST PROCESSING
OVERVIEW
Overview
Fused Deposition Modeling (FDM), or Fused Filament Fabrication (FFF), is an additive manufacturing process that belongs to the material extrusion family.
In FDM, an object is built by selectively depositing melted material in a pre-determined path layer-by-layer. The materials used are thermoplastic polymers and come in filament form.
I. A spool of thermoplastic filament is first loaded into the printer. Once the nozzle has reached the desired temperature, the filament is fed to the extrusion head and in the nozzle where it melts.
II. The extrusion head is attached to a 3-axis system that allows it to move in the X, Y and Z directions. The melted material is extruded in thin strands and is deposited layer-by-layer in predetermined locations, where it cools and solidifies. Sometimes the cooling of the material is accelerated through the use of cooling fans attached to the extrusion head.
III. To fill an area, multiple passes are required (similar to coloring a rectangle with a marker). When a layer is finished, the gantry system housing the extrusion head moves up and a new layer is deposited. This process is repeated until the part is complete.
The support structure is essential for creating geometries with overhangs in FDM because melted thermoplastic cannot be deposited in thin air. Surfaces printed on support will generally be of lower surface quality than the rest of the part. For this reason, it is recommended that the part is designed in such a way as to minimize the need for support.
Support is usually printed in the same material as the part. Support materials that dissolve in liquid also exist, but they are used mainly in high-end desktop or industrial FDM 3D printers. Printing on dissolvable supports improves significantly the surface quality of the part but increases the overall cost of a print.
FDM parts are usually not printed solid to reduce the print time and save material. Instead, the outer perimeter is traced using several passes, called the shell, and the interior is filled with an internal, low-density structure, called the infill. Infill and shell thickness affect greatly the strength of a part.
APPLICATIONS
Applications
- Prototypes for form, fit and function testing
- Prototypes directly constructed in production grade materials like ABS, Nylon
- Low-volume production of complex end-use parts
- Patterns for Sand casting & molds with lesser detailing
- Tooling / Jigs & Fixtures
MATERIALS
Materials
Ā
PLA
| TENSILE STRENGTH(MPA) | FLEXURAL STRENGTH(MPA) | IMPACT STRENGTH(MPA) | MELTING TEMPERATUREĀ°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 ā 220 |
ABS
| TENSILE STRENGTH(MPA) | FLEXURAL STRENGTH(MPA) | IMPACT STRENGTH(MPA) | MELTING TEMPERATUREĀ°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 ā 220 |
PETG
| TENSILE STRENGTH(MPA) | FLEXURAL STRENGTH(MPA) | IMPACT STRENGTH(MPA) | MELTING TEMPERATUREĀ°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 ā 220 |
Nylon
| TENSILE STRENGTH(MPA) | FLEXURAL STRENGTH(MPA) | IMPACT STRENGTH(MPA) | MELTING TEMPERATUREĀ°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 ā 220 |
Poly Carbonate
| TENSILE STRENGTH(MPA) | FLEXURAL STRENGTH(MPA) | IMPACT STRENGTH(MPA) | MELTING TEMPERATUREĀ°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 ā 220 |
Polypropelene
| TENSILE STRENGTH(MPA) | FLEXURAL STRENGTH(MPA) | IMPACT STRENGTH(MPA) | MELTING TEMPERATUREĀ°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 ā 220 |
TPU
| TENSILE STRENGTH(MPA) | FLEXURAL STRENGTH(MPA) | IMPACT STRENGTH(MPA) | MELTING TEMPERATUREĀ°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 ā 220 |
HIPS
| TENSILE STRENGTH(MPA) | FLEXURAL STRENGTH(MPA) | IMPACT STRENGTH(MPA) | MELTING TEMPERATUREĀ°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 ā 220 |
| TENSILE STRENGTH(MPA) | FLEXURAL STRENGTH(MPA) | IMPACT STRENGTH(MPA) | MELTING TEMPERATUREĀ°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 ā 220 |
DESIGN RULES
Design Rules
Minimum Wall thickness:Ā 1.2 mm
Minimum details size: 2 mm (for text/ hole diameters etc)
Layer thickness:Ā 0.1 mm ā 0.3 mm
Max dimensions: 500 x 500 x 500 mm. (For larger parts, it can be created with assembling individual parts by interlocking designs or glueing together. Please contact us for further support.)
Standard Accuracy:Ā Ā± 0.3% (with lower limit on Ā± 0.3 mm).
Lead Time:Ā Minimum 2 working days for dispatch
Surface finish: Visible layers with texture.
POST PROCESSING
Post Processing
Basic
- Support RemovalĀ
- Sanding / Polishing
Premium
- Primer
- Putty
- Coating or Painting
- Chemical Treatment
FAQs
Frequently Asked Questions
Fused Filament Fabrication (FFF) is the same process as FDM. The two terms can be used interchangeably. FFF uses a filament material that is layered and then fused, just like FDM. Fused Deposition Modeling was initially invented and trademarked by Stratysys, Inc. in 1988. The patent did not expire until 2009. To avoid trademark violations, other 3D printing companies began to reference the technology as Fused Filament Fabrication.
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