Fused Deposition Modelling (FDM)
Fused Deposition Modeling (FDM) is an additive manufacturing technology that builds parts layer by layer by extruding thermoplastic material through a heated nozzle. The process involves depositing melted material onto a build platform in a precise pattern, which then cools and solidifies to form a cohesive object.
Why use FDM?
FDM is widely used for creating durable prototypes, functional components, and tooling, utilizing a variety of thermoplastics such as ABS, PLA, and high-performance materials like Ultem. Known for its cost-effectiveness, robustness, and versatility, FDM is a popular choice across multiple industries for both prototyping and end-use applications.
Benefits of FDM
Benefits
- Cost Effective
- Reduced Leadtimes
- Large Build Envelopes
Best suited for
- Concept Modelling
- Functional Prototypes
- Manufacturing Tools
- End-Use Parts
Materials for FDM
- Ultem 9085
- ABS M-30
Using Fused Deposition Modelling (FDM) we can produce great form factor prototypes, checking jigs and fixtures.
The nature of FDM leads to very cost-effective parts and allows us to control the densities of the infill of parts. Geometry dependent, parts can be built 100% solid, semi-solid or completely hollow shells.
Cost-Effective Production
- Fused Deposition Modeling (FDM) is one of the most economical additive manufacturing technologies, making it ideal for creating durable prototypes and functional parts without high upfront costs.
- The technology uses widely available thermoplastic materials like ABS and PLA, further reducing material costs and providing a cost-efficient solution for various applications.
Robust and Functional Parts
- FDM produces strong, long-lasting parts suitable for end-use applications, tooling, and functional testing, thanks to the use of industrial-grade thermoplastics such as Ultem 9085 and ABS-M30.
- The technology excels at creating robust parts that can endure mechanical stress and thermal resistance, ensuring reliability and performance in demanding environments.
Versatility in Material Choices
- FDM supports a broad range of thermoplastics, including bio-based and high-performance materials, allowing for the production of parts with specific properties like flame retardancy, flexibility, and chemical resistance.
- The material versatility of FDM enables tailored solutions for diverse industries, from automotive and aerospace to medical and consumer products, meeting varied functional requirements.
Applications
Applications in high-performance industries:
Motorsport
- FDM is frequently used to rapidly prototype components such as aerodynamic parts, custom brackets, and interior fittings. This allows teams to quickly test and iterate designs for optimal performance and weight reduction.
- The technology produces durable tools and jigs tailored to specific vehicle components, streamlining assembly and maintenance processes. This helps in reducing downtime and improving efficiency during races.
Marine Racing
- FDM is used to create functional prototypes and end-use parts for hull fittings, propulsion systems, and other hydrodynamic components. These parts are tested for performance enhancements and customizations essential for competitive marine racing.
- The ability to use high-performance plastics like Ultem allows for the production of robust yet lightweight parts, which are crucial for improving speed and fuel efficiency in racing boats.
Advantages
Engineering advantages:
Cost-Effectiveness
FDM uses thermoplastic filaments, which are generally more affordable than other 3D printing materials, making it cost-effective for both prototyping and production.
No Need for Expensive Tooling
The process eliminates the need for costly molds and tooling, reducing overall production expenses and making small-batch production economically viable.
The FDM process overview
Preparation
A 3D model is created using CAD software and then converted into a digital format that the FDM printer can read, commonly a STL file.
The digital model is sliced into thin layers using slicing software, generating a detailed toolpath and instructions for the printer.
Material Loading
Thermoplastic filament material, such as ABS, PLA, or high-performance polymers like Ultem, is loaded into the printer. The filament is typically supplied in spools.
Printing
The FDM printer heats the thermoplastic filament to its melting point and extrudes it through a heated nozzle.
The melted material is precisely deposited onto the build platform layer by layer, following the toolpath generated during the slicing process.
Each layer cools and solidifies as the printer head moves to deposit the next layer, gradually building up the part. Support structures may be printed simultaneously if required for overhangs or complex geometries.
Post-processing
Once the print is complete, the part is removed from the build platform. Any support structures are carefully detached.
Additional post-processing, such as sanding, drilling, or painting, may be performed to achieve the desired surface finish and functionality.
