Do you want to understand the fundamentals of FDM 3D printing? We show in this article why this technology is a good option for rapid prototyping and other uses that save money and are efficient. Fused deposition modeling (FDM) 3D printing, also known as fused filament fabrication (FFF), is an additive manufacturing (AM) process within the realm of material extrusion. FDM builds parts layer by layer by selectively depositing melted material in a predetermined path. It uses thermoplastic polymers that come in filaments to form the final physical objects.
FDM is the most widely used technology in most industries and probably the first process that comes to mind when you think of 3D printing. It has the largest number of installed 3D printers worldwide. In this article, we cover the basic principles and key characteristics of this popular additive technology. We also explore the differences between FDM machines built for prototyping (desktop) and industrial applications and provide tips and tricks for engineers to get the best results from FDM 3D printing.
What it does and how it helps An FDM 3D printer works by depositing melted filament material over a build platform layer by layer until you have a completed part.
FDM uses digital design files that are uploaded to the machine itself and translates them into physical dimensions. Polymers like ABS, PLA, PETG, and PEI are used in FDM, and the machine feeds them through a heated nozzle as threads. A spool of this thermoplastic filament must first be loaded into the printer before an FDM machine can be used. Once the nozzle hits the desired temperature, the printer feeds the filament through an extrusion head and nozzle.
This extrusion head is attached to a three-axis system that allows it to move across the X, Y, and Z axes. Melted material is extruded by the printer into thin strands and deposited layer by layer along a design-defined path. Once deposited, the material cools and solidifies. In some circumstances, you can accelerate cooling by attaching fans to the extrusion head.
Similar to coloring a shape with a marker, multiple passes are required to fill an area. When the printer finishes a layer, the build platform descends, and the machine begins work on the next layer. In some machine setups, the extrusion head moves up.
This procedure is repeated until the component is completed. An FDM 3D printer makes parts by layering melted filament material over a build platform until a part is finished. FDM uses digital design files that are uploaded to the machine itself and translates them into physical dimensions. Materials for FDM include polymers such as ABS, PLA, PETG, and PEI, which the machine feeds as threads through a heated nozzle.
To operate an FDM machine, you first load a spool of this thermoplastic filament into the printer. Once the nozzle hits the desired temperature, the printer feeds the filament through an extrusion head and nozzle.
This extrusion head can move along the X, Y, and Z axes because it is connected to a three-axis system. The printer extrudes melted material in thin strands and deposits them layer by layer along a path determined by the design. Once deposited, the material cools and solidifies. You can attach fans to the extrusion head to accelerate cooling in some cases.
To fill an area, multiple passes are required, similar to coloring in a shape with a marker. When the printer finishes a layer, the build platform descends, and the machine begins work on the next layer. In some machine setups, the extrusion head moves up. This procedure is repeated until the component is completed.
What characteristics does FDM 3D printing possess? Even though the extrusion systems of FDM 3D printers and the quality of the parts produced by various machines are different, there are some characteristics that are common to all FDM printing processes. Warping
Warping is one of the most common defects in FDM. The dimensions of extruded material decrease as it cools during solidification. The dimensions of the printed part change at different rates because different areas cool at different rates. Internal stresses build up as a result of differential cooling, pulling the underlying layer upward and causing it to warp. There are several ways to prevent warping. Monitoring your FDM system’s temperature closely, particularly in the build platform and chamber, is one option. You can also increase the adhesion between the part and the build platform to mitigate warping.
Making certain choices during the design process can also reduce the likelihood of your part warping. Here are a few examples:
• Large, flat areas, such as those found on a rectangular box, are more likely to warp. Try to stay away from these as much as possible.
•Thin protruding features – think of the prongs on a fork – are also prone to warping. To prevent this, more guiding or stress-relieving material can be added at the edges of thin features to increase the area that comes into contact with the build platform.
•Sharp corners warp more often than rounded shapes, so we recommend adding fillets to the design.
• Each material is susceptible to warping in its own way. For instance, ABS is generally more sensitive to warping than PLA or PETG, for instance.
The revolutionary Stratasys FDM 3D printing process, which builds objects layer by layer using thermoplastic filament, is changing the way businesses make prototypes and finished goods. Offering a wide range of advantages, including exceptional repeatability, reduced production costs, and a wide variety of materials and applications, this innovative technology, which was introduced over three decades ago, has become the most widely adopted 3D printing technique. Stratasys FDM 3D printing empowers businesses to seamlessly transition from prototyping to full-scale production, using its remarkable speed and accuracy.
5 How It Works and Benefits
The revolutionary Stratasys FDM 3D printing process, which builds objects layer by layer using thermoplastic filament, is changing the way businesses make prototypes and finished goods. Offering a wide range of advantages, including exceptional repeatability, reduced production costs, and a wide variety of materials and applications, this innovative technology, which was introduced over three decades ago, has become the most widely adopted 3D printing technique. Stratasys FDM 3D printing empowers businesses to seamlessly transition from prototyping to full-scale production, using its remarkable speed and accuracy.
5 Key Benefits of FDM 3D Printing
Repeatability Over the last 30 years, FDM has become one of the most tried and tested 3D printing technologies, meaning the high quality, accuracy, and repeatability of FDM 3D printing enable businesses to maintain consistent and exceptional quality throughout their production processes. The unwavering precision is crucial for ensuring the integrity and reliability of manufactured components, ensuring high standards of key industries are met, and eliminating the risk of defects.
2. Numerous Material Options The material options available to users with FDM 3D printing are some of the most extensive across all 3D printing technologies. The FDM material library of Stratasys includes ABS, PC, ULTEM, carbon-reinforced nylon, and other materials. This gives manufacturers the flexibility to replicate multiple materials for some of the most difficult 3D-printed parts. Businesses save time and money by not needing to buy expensive custom-made materials because of this unparalleled adaptability, which also lets manufacturers tailor their products to specific applications.
3. Reduced Prices FDM 3D printing eliminates the need for costly tooling and expensive molds. FDM allows businesses to produce a greater number of prototypes at a fraction of the cost compared to traditional prototyping methods, as well as allowing users to produce low-volume production parts at a significantly lower cost. This opens up a wide range of new possibilities for manufacturers to experiment and innovate.
