Journal of Engineering Research and Reports

Volume 26, Issue 11, Page 304-312, 2024; Article no.JERR.126660

ISSN: 2582-2926

A Survey of Fused Deposition

Modeling (FDM) Technology in
3D Printing
Amira. A.Elsonbaty a*, Alaa MRashad a, Omnia.Y. Abass a,
Tasneem Y.Abdelghany a and Areej MAlfauiomy a
a Department Communication and Electronics, High Institute of Engineering and Technology,
New Damietta- 34517, Egypt.

Authors’ contributions

This work was carried out in collaboration among all authors. All authors read and approved the final
manuscript.

Article Information
DOI: https://doi.org/10.9734/jerr/2024/v26i111332

Open Peer Review History:

This journal follows the Advanced Open Peer Review policy. Identity of the Reviewers, Editor(s) and additional Reviewers, peer
review comments, different versions of the manuscript, comments of the editors, etc are available here:
https://www.sdiarticle5.com/review-history/126660

Received: 13/09/2024
Review Article Accepted: 15/11/2024
Published: 20/11/2024

ABSTRACT

This survey provides a thorough examination of Fused Deposition Modeling (FDM), a prevalent 3D
printing technology known for its accessibility and versatility. FDM has emerged as a transformative
tool across various industries, including healthcare, aerospace, automotive, and education. This
paper reviews recent advancements in FDM technology, focusing on material innovations,
process optimization, and application areas. We analyze the benefits and limitations of FDM,
including print quality, speed, cost-effectiveness, and environmental impact. Furthermore, we
explore emerging trends and future directions in FDM research, highlighting the potential for
enhanced customization, sustainability, and integration with other manufacturing technologies. This
survey aims to provide a comprehensive understanding of FDM's current landscape and its
implications for future developments in 3D printing.
_____________________________________________________________________________________________________

*Corresponding author: Email: [email protected];

Cite as: A.Elsonbaty, Amira., Alaa MRashad, Omnia.Y. Abass, Tasneem Y.Abdelghany, and Areej MAlfauiomy. 2024. “A
Survey of Fused Deposition Modeling (FDM) Technology in 3D Printing”. Journal of Engineering Research and Reports 26
(11):304-12. https://doi.org/10.9734/jerr/2024/v26i111332.
 Elsonbaty et al.; J. Eng. Res. Rep., vol. 26, no. 11, pp. 304-312, 2024; Article no.JERR.126660

Keywords: 3D printer; fused deposition modeling; sustainable FDM; automotive industry.

1. INTRODUCTION Fused Deposition Modeling (FDM): This

technique, among the most accessible forms of
1.1 3D Printing and Its Types 3D printing, uses thermoplastic filaments that
are heated and extruded layer-by-layer.
3D printing, or additive manufacturing, is an FDM is popular for rapid prototyping and is
innovative technology that builds objects layer commonly used in consumer-grade and
by layer, transforming digital designs into industrial machines due to its simplicity and
tangible products. Originally introduced in the affordability.
1980s, it has evolved significantly to become
a cornerstone in various industries due to Stereolithography (SLA): SLA printing
its adaptability, speed, and potential employs a UV laser to selectively harden
for cost effective, custom manufacturing. liquid resin into solid parts with high precision
Today, 3D printing is widely utilized in sectors and fine detail. This method is ideal for
such as aerospace, healthcare, automotive, applications requiring smooth surfaces and
and consumer goods. This technology has intricate detail, such as dental models and
not only streamlined production but has medical devices, making it especially popular in
also empowered designers and engineers to the healthcare industry.
produce prototypes and end-use parts with
unprecedented precision, directly from CAD Selective Laser Sintering (SLS): This
models. technique uses a high-powered laser to sinter
powdered material, typically nylon or polymers,
The main advantage of 3D printing lies in its into durable, functional parts. SLS is
ability to create complex shapes without the particularly valuable in industrial applications
need for molds or cutting tools, distinguishing it where strength and complex geometries are
from conventional subtractive manufacturing required, as it does not require additional support
methods. Through different techniques, each structures during printing.
with unique capabilities and materials, 3D
printing can meet a wide range of Multi-Jet Printing (MJP): In MJP, multiple
application needs (Yan et al., 2018). print heads deposit material droplets, which
are then cured to form highly detailed parts
1.2 Types of 3D Printing Technologies with a high degree of accuracy. MJP is
commonly used in jewelry design, engineering
Several primary types of 3D printing models, and any application where fine
technologies have emerged, each suited to detail and multi-material capabilities are
specific purposes and materials: advantageous.

Fig. 1. 3d printer
Source: https://www.rennd.com/blog/polyjet-3d-printing/

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2. INTRODUCTION FUSED DEPOSITION seeks to highlight the potential of FDM

MODELING as a transformative technology in modern
manufacturing.
Fused Deposition Modeling (FDM) has gained
significant traction as a prominent additive 3. RECENT ADVANCES IN FDM
manufacturing technology since its inception in
the late 1980s. This technique involves the The diverse applications of FDM technology
layer-by-layer deposition of thermoplastic across various fields highlight its potential for
materials to create three- dimensional objects, innovation in medicine, environmental science,
making it highly versatile for various applications. and engineering. Continued advancements
The advantages of FDM include its cost- promise to enhance the capabilities and
effectiveness, ease of use, and the ability to efficiency of 3D printing. The study (3D Printer
produce complex geometries that are often Particle Emissions 2006) investigates the
difficult to achieve with traditional manufacturing emissions of ultrafine particles from FDM
methods. As a result, FDM has found printers, particularly focusing on the inhalation
applications across diverse sectors, including exposure risks for children and adults. It utilizes
healthcare for prosthetics and implants, dosimetry models to estimate particle
aerospace for lightweight components, and deposition in the respiratory tract, highlighting
education for prototyping and design projects the health risks associated with frequent use of
(Mwema & Akinlabi 2020). FDM printers. The review in ((FDM 2023)
discusses the FDM process, emphasizing
Recent advancements in material science have the rheological properties of thermoplastic
expanded the range of thermoplastics that can materials used in 3D printing. It covers the
be used in FDM, including biodegradable importance of these properties in ensuring
options and composite materials that enhance printability and the overall performance of
mechanical properties (Sun & Soh 2015). printed objects. In paper (Mwema & Akinlabi
Moreover, improvements in printing technology, 2020) reviews the applications of FDM in the
such as increased resolution and speed, pharmaceutical industry, focusing on the
have further enhanced the practicality of FDM production of drug delivery systems and the
for industrial applications (Crafts et al. 2016). challenges faced in implementing this
Despite its advantages, challenges remain, technology in medical applications. In review
particularly concerning the mechanical (Yan et al. 2018) highlights various 3D printing
properties of printed parts and the limitations technologies, including FDM, and their
of certain materials (Ursan et al. 2013). applications in medicine. It discusses the
potential for personalized medicine and the
This survey aims to provide a comprehensive challenges of regulatory approval. The
overview of the current state of FDM structured review (Ursan et al. 2013) examines
technology, including recent innovations, the use of 3D printing in drug formulation,
applications, and future trends. By synthesizing focusing on FDM technology and its ability to
findings from recent literature, this paper create customized drug delivery systems.

Fig. 2. FDM 3D Printer

Source: https://biohub3d.com/que-tipos-de-impresion-3d-tenemos-guia-completa/

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The research (Sun & Soh 2015) explores the especially for custom or complex shapes that
potential of FDM in creating tablets with would be more costly to produce through
customizable release profiles, demonstrating the traditional methods. This approach is particularly
technology's application in personalized useful in industries like medical and aerospace,
medicine. The (Crafts et al. 2016) discusses the where customization and precision are critical.
applications of 3D printing, including FDM, in FDM allows for on-demand manufacturing,
surgical planning and the production of surgical reducing inventory and storage costs (Lee &
instruments in the field of otolaryngology. The Park 2022).
pilot study (Williams et al., 2015) reviews the use
of FDM in podiatry, focusing on the production of 4.4 Educational and Research
custom orthotics and the benefits of personalized Applications
treatment. The (Rankin et al., 2014) evaluates
the current state of 3D printing technologies, Applications are valuable in educational
including FDM, in the production of surgical institutions and research labs for instructional
instruments, discussing the potential for purposes and experimentation with complex
customization and efficiency. The (Kim et al., designs. In these environments, FDM
2020) study presents a novel application of FDM enables hands-on experience in manufacturing
in creating water filtration systems, showcasing techniques, supporting students and researchers
the versatility of 3D printing in addressing in fields such as engineering, product design,
environmental issues. and medical sciences (Johnson 2022).

4. APPLICATIONS OF FDM 3D PRINTING 5. ADVANTAGES AND LIMITATIONS OF

IN MODERN MANUFACTURING FDM 3D PRINTING
4.1 Prototyping and Product 5.1. Advantages of FDM 3D Printing
Development
5.1.1 Cost-effectiveness
FDM 3D printing is widely used for rapid
prototyping, which accelerates the product FDM is one of the most affordable types of 3D
development cycle by enabling manufacturers to printing, both in terms of equipment and
quickly produce physical models of product material cost. The method uses thermoplastic
designs. This method allows companies to filaments, which are relatively inexpensive and
evaluate, modify, and validate designs at a lower widely available. This cost-effectiveness
cost and faster turnaround than traditional has made FDM accessible for small
methods the automotive industry, prototyping businesses, educational institutions, enabling
with FDM helps test form and fit, allowing for rapid prototyping and small- scale manufacturing
multiple iterations without incurring high without high investments (Chen & Martinez
expenses (Smith & Chen 2023). 2022).

4.2 Tooling and Fixtures 5.1.2 Use and accessibility

Manufacturers use FDM to produce custom FDM printers are known for their ease of use,
tools, jigs, and fixtures, which are essential in requiring minimal technical expertise compared
assembly lines to maintain accuracy and to other 3D printing technologies. This
efficiency. This application costs, and allowing for accessibility makes FDM suitable for educational
easy adjustments in design based on specific environments, allowing students and new users
improves operational efficiency by reducing lead to experiment and learn 3D printing techniques
times for tools, lowering material manufacturing without extensive training. Additionally, FDM
needs. Boeing and other companies, for printers are compatible with a variety of
instance, employ FDM for fabricating custom materials, enhancing versatility in applications
tooling, enhancing flexibility in production (Brown ranging from product design to engineering
et al. 2022). (Williams et al. 2023).

4.3 End-Use Partsolume Production 5.1.3 Viability

FDM is becoming increasingly viable for low- FDM allows for highly customized designs and
volume production runs of end-use parts, geometric complexity that would be challenging

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with traditional manufacturing methods. This 5.2.4 Warping and material constraints
flexibility supports innovation in fields like
medical device production and aerospace, where Certain thermal in FDM, like ABS, are prone to
unique geometries are often required. With FDM, warping, which can affect dimensional accuracy
custom parts can be produced on-demand, and cause part failures. Warping typically results
significantly reducing lead times and inventory from uneven cooling, especially in larger parts,
requirements (Zhao & Smith 2021). making the process sensitive to environmental
conditions and design features. Material
5.1.4 Sustainable FDM constraints also limit FDM’s use in applications
requiring specific material properties, such as
It reduces waste by only using the necessary chemical resistance (Sanchez & Weaver 2023).
amount of material to build an object, contrasting
with subtractive manufacturing methods that 6. CASE STUDIES AND REAL-WORLD
generate excess material. Additionally, bio-based EXAMPLES OF FDM 3D PRINTING
and recycled filaments are becoming more
common, further enhancing FDM’s role in 6.1 Automotive Industry: Prototyping at
sustainable manufacturing practices (Green Ford Motor Company
2022).
Ford Motor Company has been a pioneer in
5.2 Limitations of FDM 3D Printing using FDM for prototyping and testing new
vehicle parts. Ford uses FDM to create prototype
5.2.1 Surface finish and accuracy parts, which allows the team to assess design
accuracy, functionality, and fit before committing
FDM printing can lead to relatively low-resolution to production. This approach has resulted in
finishes, with visible layer lines that may require significant reductions in lead time and
post-processingfor smoothness and aesthetic prototyping costs. Ford has reported that FDM-
appeal. While advancements are improving based prototyping enables a 40% faster
accuracy, FDM is generally less precise turnaround for parts and contributes to its goal of
compared to stereo lithography (SLA) or reducing product development time across its
selective laser sintering (SLS), making it less vehicle lineup (Brown et al. 2023).
ideal for applications demanding high detail or
smooth surface textures (Jackson & Li 2023). 6.2 Healthcare: Custom Prosthetics and
Orthotic Devices
5.2.2 Limited Material Strength
In the healthcare industry, FDM has been
Although FDM supports arange of
instrumental in producing custom prosthetics and
thermoplastics, including ABS and PLA; it is
orthotic devices tailored to individual patient
generally limited in producing parts that require
needs. Startups like Limitless Solutions utilize
high strength or durability. Parts created with
FDM to create prosthetic limbs for children,
FDM are often weaker along the layer lines, and
providing a low-cost, highly customized solution
while composites like carbon-fiber-reinforced
that traditional manufacturing methods cannot
filaments exist, they are more expensive
easily achieve. The FDM process allows for fast
and may still not match the strength
adjustments based on growth or specific patient
provided by other manufacturing methods (Kim
feedback, ensuring optimal comfort and
et al. 2021).
functionality (Wang & Chen 2022).
5.2.3 Slow Printing speed for large parts
6.3 Aerospace: Tooling at Boeing
The Ayer approach of FDM can lead to long
production times, especially for larger or more Boeing has incorporated FDM 3D printing to
intricate parts. For industrial-scale applications produce jigs, fixtures, and other essential tooling
requiring high throughput, FDM may not be the components. Using FDM for these applications
most efficient choice. Technologies like SLS or enables Boeing to quickly produce lightweight,
multi-jet fusion are often preferred for larger durable, and cost-effective tooling. In one notable
production runs due to their faster speeds and example, Boeing used FDM to produce assembly
ability to handle more complex geometries aids for aircraft fuselage assembly, which
(Jones& Patel). reduced tooling production time by 60% and

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resulted in substantial cost savings. The 7.2 Layer Adhesion and Anisotropy
company continues to explore FDM applications
to improve operational efficiency and reduce A limitation in FDM is the anisotropy of printed
weight on non-critical flight components (Zhang parts, where mechanical properties vary based
& Lee 2021). on print direction. Parts are generally strongest
along the layer lines, while strength between
6.4 Consumer Products: Customizable layers may be weaker. Research in 2024 has
Wearables by Adidas made strides in optimizing layer adhesion
through new print strategies and advanced
Adidas has embraced FDM technology to materials, reducing this anisotropy and thus
develop customizable footwear and wearable expanding the range of FDM’s industrial
accessories. With FDM, Adidas can rapidly applications.
prototype new designs and create custom
insoles that match individual customer 7.3 Fatigue Resistance
requirements for fit and comfort. The company
has also leveraged FDM to explore sustainable FDM parts also exhibit moderate fatigue
product lines, incorporating biodegradable resistance, depending on material choice and
materials in the production of prototypes print parameters. This is essential in applications
and specialized footwear. This application where repeated loading occurs, as in machine
underscores FDM’s potential in creating components or prosthetic devices. Studies reveal
personalized products and promoting eco- that nylon-based filaments exhibit higher fatigue
friendly manufacturing (Garcia et al. 2022). resistance, suitable for parts under cyclic loading
(https://all3dp.com/1/types-of-3d-printers-3d-
6.5 Education and Research: University printing-technology/8/11/2024).
Engineering Projects
8. FUTURE TRENDS AND IMPLICATIONS
FDM is widely adopted in educational institutions FOR THE MANUFACTURING INDUS-
to support engineering and design projects. For TRY
example, at MIT, students use FDM 3D
printing to create components for robotics, 8.1 Expansion of Material Options
biomedical devices, and mechanical prototypes,
which allows them to experiment with Future advancements in FDM materials are likely
real-world engineering challenges in a to enhance the mechanical, thermal, and
low-risk environment. Studies show that hands- chemical properties of printed parts. Research is
on experience with FDM significantly improves ongoing to develop high-strength, bio-based, and
students’ understanding of design principles and composite filaments that expand the range of
manufacturing processes, making it a vital applications for FDM, making it more
educational tool (Smith & Turner 2023). competitive with traditional manufacturing.
Companies are exploring carbon-fiber-reinforced
7. MECHANICAL PROPERTIES OF FDM thermoplastics, conductive filaments, and
PARTS biodegradable polymers, which could make FDM
viable for highly specialized sectors such as
7.1 Tensile Strength aerospace, medical, and electronics
(https://all3dp.com/1/types-of-3d-printers-3d-
FDM parts generally exhibit good tensile printing-technology/8/11/2024).
strength, which refers to the material's ability to
resist tension and withstand stretching forces. 8.2 Integration with Smart Manufacturing
The tensile strength varies based on material and IoT
choice, layer height, and print orientation, with
filaments such as ABS and carbon-fiber- Integrating FDM technology with the Internet
reinforced materials yielding higher strength in of Things (IoT) and smart manufacturing systems
specific orientations. For example, studies in will enable more autonomous, connected
2024 show that optimized layer bonding and manufacturing processes. IoT-enabled FDM
fiber-reinforced materials significantly enhance printers could improve efficiency by providing
tensile strength, making FDM suitable for real-time monitoring, predictive maintenance,
functional prototypes and end-use parts. and data-driven insights, reducing downtime and

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material waste. This shift aligns with enabling rapid prototyping, cost-effective
Industry 4.0, where interconnected machines production, and highly customizable solutions
enhance the scalability and adaptability of across industries such as automotive,
manufacturing operations, allowing for seamless healthcare, and aerospace. The advantages
on-demand production (Miller & Wang 2023). of FDM—its affordability, ease of use, and
design flexibility—have made it an accessible
8.3 Increased Customization and On- option for businesses and educational
Demand Production institutions alike. However, limitations related to
surface finish, material strength, and production
FDM’s role in on-demand, customizable speed highlight areas where continued
production is expected to grow as industries innovation is essential.
prioritize personalized products. This trend is
particularly evident in the medical and wearable Case studies demonstrate the real-world impact
sectors, where tailored devices and products of FDM, from custom prosthetics to lightweight
are essential. As FDM becomes more efficient aerospace tooling, showcasing its potential to
and reliable, companies will increasingly adopt revolutionize manufacturing practices. Looking
it for short-run manufacturing and custom ahead, the integration of advanced materials,
items, minimizing the need for large IoT capabilities, and sustainable practices are
inventories and improving the flexibility of supply likely to drive FDM’s evolution. These
chains (Thomas & Nguyen 2022). advancements will empower manufacturers to
meet the demands for on-demand production
8.4 Sustainability and Eco-Friendly Manu- and eco- friendly practices, positioning
facturing FDM as a key technology in the era of
Industry 4.0. Ultimately, while FDM will
With sustainability becoming central to complement rather than replace traditional
manufacturing, FDM’s potential for waste manufacturing, its role will continue to
reduction and use of biodegradable materials expand, offering new opportunities for
supports eco-friendly practices. Future trends innovation, customization, and efficiency in the
may see the development of entirely circular manufacturing industry.
FDM manufacturing systems, where materials
can be reused or composted. This approach DISCLAIMER (ARTIFICIAL INTELLIGENCE)
aligns with global efforts to reduce carbon
emissions, providing companies with Author(s) hereby declare that NO generative AI
sustainable options for prototyping and low- technologies such as Large Language Models
volume production (Green et al. 2021). (ChatGPT, COPILOT, etc) and text-to-image
generators have been used during writing or
8.5 Advancements in Multi-Material and editing of this manuscript.
Multi-Color Printing
COMPETING INTERESTS
Future FDM systems are expected to
incorporate multi-material and multi-color Authors have declared that no competing
capabilities, allowing for more complex and interests exist.
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