✦ Principle ✦ Fused deposition modeling (FDM) (and its close relative, fused filament fabrication (FFF)) is an additive manufacturing process presented by extruding thermoplastic filaments through a heated nozzle, solidifying layer by layer to create the desired object.
✦ Accuracy ✦ Generally offers lower accuracy and resolution compared to SLA and SLS, but advancements have improved its precision.
✦ Strength ✦ FDM parts tend to have moderate strength, with layer adhesion being a factor affecting overall strength.
✦ Cost ✦ FDM printers are often more affordable compared to SLA and SLS printers, and materials are relatively inexpensive.
In 1989, Scott Crump and his wife Lisa Crump, co-founders of Stratasys Inc., developed Fused Deposition Modeling (FDM). Inspired by Scott’s attempt to create a toy frog for his daughter using plastic, candle wax, and a hot glue gun, they automated the process to build objects layer by layer. The FDM technology quickly gained popularity, initially with hobbyist 3D printers in the late 2000s, followed by industrial-grade machines. The expiration of the FDM patent in 2009 made the technology widely accessible, leading to a surge in commercial, DIY, and open-source 3D printer applications.
✦ Stratasys - uPrint® SE Plus ✦
✦ Materials ✦
There's a wide range of materials available but typically limited to thermoplastics.
Commonly used materials include:
PLA
ABS
PETG
TPU
ASA
Nylon
FDM printers is prepared by loading a spool of thermoplastic filament (such as PLA, ABS, or PETG) into the printer's extruder/first nozzle. The printer's build platform is leveled and optionally coated with a material like painter's tape or a specialized build surface to help with adhesion. Also, FDM requires a sacrificial support material that is deposited via a second nozzle.
The fused deposition modeling (FDM) printing process involves several key steps:
✦ Printing Process:
✦ Cooling and Solidification:
✦ Finishing:
✦ Aerospace ✦
Fused Deposition Modeling (FDM) technology is making significant strides in aerospace applications. By utilizing FDM, aerospace engineers can produce lightweight yet robust parts, reduce manufacturing time, and even create complex geometries that were once challenging or impossible to achieve. From prototyping to producing end-use parts, FDM enables rapid iteration and customization while maintaining high precision and reliability. This technology plays a crucial role in streamlining production processes and enhancing the performance of aerospace components.
✦ Automotive Industry ✦
FDM technology in the automotive industry provides rapid prototyping, functional testing, and end-use part manufacturing; enables quick iteration, reduces development cycles, and lowers costs; produces durable parts for harsh environments; facilitates on-demand production and minimizes waste.
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✦ Aerospace ✦
Prototyping of aircraft parts, manufacturing lightweight components, creating tooling and fixtures.
✦ Healthcare ✦
Producing custom prosthetics, anatomical models for surgical planning, and medical device prototypes.
✦ Education ✦
Teaching STEM concepts through 3D printing, creating educational models and prototypes.
✦ Architecture ✦
Creating architectural models, prototyping building components, and fabricating scale models of structures.
✦ Consumer Goods ✦
Customizing product designs, manufacturing prototypes and end-use parts for consumer electronics and household items.
✦ Jigs and Fixtures ✦
FDM technology is commonly used for 3D printing jigs and fixtures in manufacturing and assembly processes. These custom tools aid in holding, aligning, or guiding parts during production, improving efficiency, accuracy, and repeatability. FDM-printed jigs and fixtures offer benefits such as cost-effectiveness, rapid customization, and the ability to withstand industrial environments. They are utilized in various industries including automotive, aerospace, electronics, and healthcare for tasks like assembly, quality control, and testing.
Assembly Fixtures
End-of-Arm Tooling
