Fused Deposition Modeling (FDM)

What is FDM 3D Printing??

Fused deposition modeling (FDM) 3D printing is an additive manufacturing (AM) process, which is widely known for its accuracy, speed, low cost, and sustainable quality parts. Computer-Aided Design (CAD) files are converted to Standard Triangle Language (STL) format and then uploaded to slicing software which calculates and creates a G-code file, thereafter, sends it to the printer to begin building. Like material extrusion, FDM uses thermoplastic polymers that are turned into spools of filament. The filament is melted, then dispensed through a nozzle that selectively places material layer by layer onto a build plate until a build is complete. Being a highly cost-effective process, standard FDM prints are not generally 100% dense but can be adjusted based on the building requirements. Most FDM prints have a 20-50% infill (the inside of the shell creating the internal structure) and a 2-6mm thick shell (the outermost layer of a part) for sustainable prints.?

Industrial/Professional VS. Desktop FDM 3-D Printers?

Not all FDM printers are the same. Today, there are two different types of FDM printers. The first is a desktop FDM printer. Desktop printers are great for your average at-home enthusiast. Typical desktop printers use filaments like Acrylonitrile butadiene styrene (ABS), Polylactic acid (PLA), Polyethylene terephthalate glycol (PETG), and Polyetherimide (PEI) which are bought in spools of ? to 3 kg and print at lower temperatures compared to industrial printers. These printers have become much more affordable over the past 5 years.?

The second type is an industrial or professional FDM 3D printer. These printers are mainly used in manufacturing. Industrial FDM printers are different from desktop printers due to their increased accuracy, build plate size, cost, and ability to print materials with advanced material properties. The wide range of material choices allows for the printed parts to be used in many different industries such?

as automotive, aerospace, defense, semi-conductors, and medical. Polymers that have high impact strength, chemical resistance, thermal stability, and biocompatibility like Polyetheretherketone (PEEK), Polycarbonate (PC), Nylon (PA-11), etc. can all be used with industrial FDM printers.?

EPTAM’s FDM 3-D Printing Capabilities and Uses:?

EPTAM has over 25 FDM printers, with the largest build plate of 12in X 12in X 23.8in. These FDM printers allow EPTAM to deliver final products or prototypes as a quick, reliable, high-quality, low-cost solution to our customers.?

Prior to FDM printing, the cost of manufacturing parts was expensive and time-consuming. Parts would undergo extensive planning to determine the most efficient way to manufacture a good quality part. The low cost and rapid turnaround with FDM printing have changed that process, allowing for quick, seamless solutions.?

Due to the quick build times and low cost, FDM printers are a great resource for EPTAM’s internal engineering and quality teams. EPTAM uses FDM printers for many in-house projects including fixtures, various prototype solutions, and workbench organizers, that help support seamless process flow and line clearance on the manufacturing floor.?

Is FDM the Right Choice:?

Before determining if FDM is the right process, key factors to consider are the design of your part and its application. When designing parts to be manufactured on an FDM printer, it is important to note that every machine has its limitations. To ensure you have a successful design, the number of large flat areas and sharp edges need to be limited to avoid warping that can occur when printing. Initially, it can take a few attempts to ensure settings are correct for printing a newly designed part. A secondary operation is recommended for small holes and threads, due to the material fusing together in small areas.?

Parts printed on FDM printers generally need support structures to be used on areas that overhang the build plate and on features with bridges that have greater than a 45° angle.?

It is best to limit the number of supports needed due to the low print resolution when printing on supports.?

EPTAM currently has 0.2, 0.4, 0.6, and 0.8mm nozzle sizes. Features smaller than the nozzle diameter cannot be achieved, and wall thicknesses must be 2 to 3 times thicker than the nozzle diameter.?

FDM Conclusion:?

Striving to deliver the best products to our customers, EPTAM uses FDM printers daily to engineer projects and support customers’ needs. FDM printers are an excellent resource for producing quick, functional, high-quality parts.?

Start your next FDM project with us today! Connect with our experts here: eptam.com

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References:?

What is FDM (fused deposition modeling) 3D printing? Hubs. (n.d.). Retrieved September 29, 2022, from https://www.hubs.com/knowledge-base/what-is-fdm-3d-printing/