FDM-Fused Deposition Modeling
Technology 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 a 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 on 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 build platform moves down (or in other machine setups, the extrusion head moves up) and a new layer is deposited. This process is repeated until the part is complete.
Material & Property
| Material | Tensile Strength | Yield Strength | Young Modulus (Modulus Of Elasticity) | Elongation At Break | Flexural Strength | Impact Strength |
|---|---|---|---|---|---|---|
| PLA | 50-70 MPa | 45-60 MPa | 2-3k MPa | 4-10 % | 80-110 MPa | 2-6 kJ/m² |
| ABS | 30-50 MPa | 20-40 MPa | 1-2.4k MPa | 5-20 % | 50-80 MPa | 10-20 kJ/m² |
| PETG | 45-55 MPa | 40-50 MPa | 1.9-2.1k MPa | 5-15 % | 60-80 MPa | 5-10 kJ/m² |
| NYLON | 50-80 MPa | 40-70 MPa | 0.8-2k MPa | 20-30 % | 50-90 MPa | 10-15 kJ/m² |
| Poly Carbonate | 55-75 MPa | 50-70 MPa | 2-2.5k MPa | 5-10 % | 80-100 MPa | 20-30 kJ/m² |
| TPU | 25-50 MPa | 20-40 MPa | 10-25 MPa | 200-600 % | NA | 5-50 kJ/m² |
Applications
- High-Precision Prototyping for Detailed Designs
- Custom Dental and Orthodontic Appliances
- Intricate Jewelry and Fashion Accessories
- Medical Models and Surgical Planning Tools
- Complex Engineering Components
- Detailed Miniatures and Figurines
Design Consideration for FDM
Minimum Wall Thickness: 1.2 mm
Minimum Details Size: 2 mm (for text, hole diameters, etc.)
Layer Thickness: 0.1 mm – 0.3 mm
Max Dimensions: 220 x 220 x 200 mm.
Standard Accuracy: ± 0.3% (with a limit of ± 1 – ± 0.3 mm)
Lead Time: Minimum 2 working days for dispatch
Surface Finish: Visible layers with texture
Embossed/Engraved Details: 0.4 mm
Post Processing
Basic: Support Removal & Sanding / Polishing
Add-on: Primer, Putty, & Coating / Painting