FUSED DEPOSITION
MODELLING(FDM) IN
DETAIL
FUSED DEPOSITION MODELLING
INTRODUCTION
Fused Deposition Modelling (FDM)
Fused Deposition Modelling (FDM) is sometimes called Fused Filament Fabrication (FFF) one of the most
widely used manufacturing technologies for rapid prototyping today. FDM fabricates a 3D model by
extruding thermoplastic materials and depositing the semi molten materials onto a stage layer by layer.
Which dispenses two materials – one material to build the part and the other material for a disposable
support structure. Two separate nozzles are used for model material and support material. The recycling
of thermoplastics is an established process for converting waste into useful products. Fused deposition
modelling (FDM) is low cost extrusion based 3-dimensional (3D) printing technology which fits very well in
frame work of primary and secondary recycling. As shown in the schematic process in Figure 4,
thermoplastic filaments, the material used to build 3D models, are moved by two rollers down to the
nozzle tip of the extruder of a print head, where they are heated by temperature control units to a semi
molten state. .As the print head traces the design of each defined cross-sectional layer horizontally, the
semi molten materials are extruded out of the nozzle and solidified in the desired areas. The stage then
lowers and another layer is deposited in the same way. These steps are repeated to fabricate a 3D
structure in a layer-by-layer manner. The outline of the part is usually printed first, with the internal
structures (2D plane) printed layer by layer. The nozzle has a programmed mechanism that allows the
flow of the melted material to be turned on and off. Surface defects from this particular process include
staircase and chordal effects resulting from the nature of the slicing software and .STL file format. Internal
defects can result from heterogeneities in the filament feed diameter and density, as these can affect
how the material is extruded from the printer nozzle.
WORKING OF FUSED DEPOSITION
MODELLING PRINTER
Characteristics of FDM
Printer Parameters
Warping
Layer Adhesion
Support Structure
Infill & Shell Thickness
Main Parts Of FDM 3D Printers
STEPS IN FDM 3D PRINTING
Conceptualization.
CAD
Conversion to STL
Transfer to AM.
STL file manipulation.
Machine setup.
Build.
Removal and clean up.
Post processing.
CAD model
A cad model
is needed for
printing a 3D
part, it can
be done in
3d software
Conversion to STL
STL is the standard
file type used by
most or all rapid
prototyping
systems. A STL is a
triangulated
representation of a
3D CAD model.
Machine setup & Build.
Process Parameters in FDM
Post Processing
FDM parts can be finished to a very high
standard using various post-processing
methods, such as sanding and polishing,
priming and painting, cold welding, vapor
smoothing, epoxy coating and metal
plating
Post processing for FDM printed
parts
Support Removal
Sanding
Cold welding
Gap filling
Polishing
Priming & painting
Vapour smoothing
Dipping
Epoxy coating
Rules of Thumb
FDM can produce prototypes and functional parts fast and at a low
cost from a wide range of thermopalstic materials.
The typical build size of a desktop FDM 3D printer is 200 x 200 x 200
mm. Industrial machines have a larger build size.
To prevent warping avoid large flat areas and add fillets in sharp
corners.
FDM is inherently anisotropic, so it is not recommended for
mechanically critical components.
Common FDM Materials
Nylon.
Acrylonitrile Butadiene Styrene (ABS).
Polycarbonates.
ply-lactic acid (PLA).
Polystyrene.
Thermoplastic urethane.
Material & its Characteristics
Material Characteristics
Good strength
ABS Good temperature resistance
More susceptible to warping
Excellent visual quality
PLA Easy to print with
Low impact strength
High strength
Nylon (PA) Excellent wear and chemical resistance
Low humidity resistance
Food Safe*
PETG Good strength
Easy to print with
Very flexible
TPU
Difficult to print accurately
Excellent strength to weight
PEI Excellent fire and chemical resistance
High cost
A few advantages of FDM 3D
printers include:
A wide range of FDM printers are available in the market
today
the raw material is inexpensive, durable and maintains
dimensional integrity
there is a wide choice of raw material
they are affordable
low turnaround time
One disadvantage is that if the desired level of accuracy is
extremely high, then the FDM printers may be found wanting.
FDM 3D Printers find application
in:
Automotive
Aerospace
Manufacturing
Industrial
Medical
Architecture
Consumer Goods
Fashion
Education & Research
