FDM Printing

About FDM

Fused Deposition Modelling (FDM), a widely accessible form of 3D printing, is an advanced manufacturing technology that constructs parts layer by layer. It uses a process of selectively depositing melted plastic to form the object from the bottom up. The modelling software first slices the 3D CAD file into layers, creating a path for the nozzle to follow during the printing process.

How FDM Printing Works

FDM printers heat thermoplastic materials to a semi-liquid state and then deposit them in fine beads along the predetermined path. When additional support structures are required, the printer deposits a removable material that acts as scaffolding. These supports can later be dissolved in a water and detergent solution or manually removed, leaving behind the final part.

Benefits of FDM Printing

FDM enables practical production of complex geometries and cavities, utilising thermoplastics similar to those used in conventional manufacturing processes.
It caters to applications requiring tight tolerances, toughness, environmental stability, and specialised properties like electrostatic dissipation, translucence, biocompatibility, VO flammability, or FST ratings.
FDM parts are incredibly durable, making them ideal for testing for fit and function and for prototypes that must withstand extreme temperatures, mechanical stress, and chemical corrosion.
FDM is also effective for creating final products, particularly smaller, detailed objects. It's commonly used in the automotive industry for creating smaller prototypes.

Materials Used in FDM Printing

High-Performance Plastic Polymers: These include thermosets and thermoplastics such as ULTEM®. Thermosetting polymers harden irreversibly after curing, forming chemical bonds that prevent re-melting even under high heat. Thermoplastics, on the other hand, soften when heated and solidify upon cooling. They can be repeatedly melted and reshaped.
ULTEM® (Polyetherimide or PEI): A high-performance amorphous thermoplastic resin known for its high-temperature mechanical integrity. It's strong, chemical- and flame-resistant, and maintains stable electrical properties under extreme conditions. ULTEM is widely used in the aerospace industry, as well as for circuit boards, food preparation, and sterilisation equipment.

Applications of FDM Printing

Design Verification: FDM is excellent for testing parts for fit and function, allowing for rapid prototyping and verification of CAD models regarding strength and durability.
Production Runs: FDM can be a cost-effective solution for batch production of items like promotional materials, internal components, and casings.
Durability: FDM is preferable for more durable and tolerant parts.