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Fused Deposition Modeling (FDM)
Fused Deposition Modeling (FDM)
- FDM technology can go about building quick prototypes with strength and speed, at a very economical price in a range of thermoplastic materials, which makes it a very attractive option.
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Overview
Applications
Materials
Specifications
Post Processing
FAQ
Overview
3D printing utilizing the extrusion of thermoplastic material is easily the most common and recognizable 3DP process. The most popular name for the process is Fused Deposition Modelling (FDM).
The process works by melting plastic filament that is deposited, via a heated extruder, a layer at a time, onto a build platform according to the 3D data supplied to the printer. Each layer hardens as it is deposited and bonds to the previous layer. The FDM/FFF processes require support structures for any applications with overhanging geometries.
The great advantage of FDM is the durable materials it uses, the stability of their mechanical properties over time, and the quality of the parts. The production-grade thermoplastic materials used in FDM are suitable for detailed functional prototypes, durable manufacturing tools and low-volume manufacturing parts.
Support structures, or lack thereof, have generally been a limitation of the entry level FFF 3D printers. However, as the systems have evolved and improved to incorporate dual extrusion heads, it has become less of an issue. Occasionally, the process can be slow for some part geometries and layer-to-layer adhesion can be a problem, resulting in parts that are not watertight.
Applications
- Prototypes for form, fit and function testing
- Prototypes directly constructed in production materials like ABS, Nylon
- Low-volume production of complex end-use parts
- Patterns for Sand casting & molds with lesser detailing
materials
PLA
| Tensile Strength(MPa) | Flexural Strength(MPa) | Impact Strength(MPa) | Melting Temperature°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 – 220 |
ABS
| Tensile Strength(MPa) | Flexural Strength(MPa) | Impact Strength(MPa) | Melting Temperature°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 – 220 |
PETG
| Tensile Strength(MPa) | Flexural Strength(MPa) | Impact Strength(MPa) | Melting Temperature°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 – 220 |
Nylon
| Tensile Strength(MPa) | Flexural Strength(MPa) | Impact Strength(MPa) | Melting Temperature°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 – 220 |
Poly Carbonate
| Tensile Strength(MPa) | Flexural Strength(MPa) | Impact Strength(MPa) | Melting Temperature°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 – 220 |
Wood
| Tensile Strength(MPa) | Flexural Strength(MPa) | Impact Strength(MPa) | Melting Temperature°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 – 220 |
Flexible
| Tensile Strength(MPa) | Flexural Strength(MPa) | Impact Strength(MPa) | Melting Temperature°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 – 220 |
HIPS
| Tensile Strength(MPa) | Flexural Strength(MPa) | Impact Strength(MPa) | Melting Temperature°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 – 220 |
PVA
| Tensile Strength(MPa) | Flexural Strength(MPa) | Impact Strength(MPa) | Melting Temperature°C |
|---|---|---|---|
| 62.63 | 65.02 | 4.28 | 190 – 220 |
specifications
Minimum Wall thickness: 1.2 mm
Minimum details size: 2 mm (for text/ hole diameters etc)
Layer thickness: 0.1 mm – 0.3 mm
Max dimensions: 650 x 600 x 600 mm. Large parts can be created with assembling individual parts by interlocking designs or glueing together.
Standard Accuracy: ± 0.3% (with lower limit on ± 0.3 mm).
Lead Time: Minimum 2 working days for despatch
Surface finish: visible layers with texture.
post processing
Basic: Support Removal, Sanding, Smoothing
Add on: Primer, Coating/ Painting
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Clients
Think3D has been a great partner for us in supplying COVID-19 test cartridges on-time despite the pandemic challenges. When we came up with a new requirement needing a workforce of more than 25 people, think3D took up the challenge and arranged the workforce within 2 days. I highly recommend think3D for any manufacturing needs.
Sanket Srivatsav
Production In-Charge, Molbio
As a professor doing research on new materials, I needed a strong industry partner to assist us. think3D perfectly fit that bill. think3D team is highly knowledgeable on all manufacturing technologies and the team is very prompt in responding to all our requests. My research has been very successful, thanks to think3D team.
Dr. Karthik Chetan V
Asst. Professor, BITS Pilani
We found issue with one part at the time of assembly and needed a quick replacement. think3D team has quickly responded to our request, redesigned the part and printed it using metal 3D Printing and delivered in 3 days time. The part came out really well and the design was better than that of the actual one.
Rama Krishna
Senior Manager (IMM), BDL
FAQS
Frequently Asked Questions
FDM stands for Fused Deposition Modeling, which simply means that material is deposited in single layers that fuse together to create a 3D object.
Stereolithography (SLA) printing was first invented in the 1980’s and works by curing resin with light. The light solidifies a liquid resin via a process called photo-polymerization and builds objects layer by layer.
Additive manufacturing, or 3D printing, is the process of turning digital designs into three-dimensional objects.During SLS, tiny particles of plastic, ceramic or glass are fused together by heat from a high-power laser to form a solid, three-dimensional object.
What technology is used in 3d printing?
3D Printers and 3D Printing: Technologies, Processes and Techniques. 3D printing is also called additive manufacturing. This term accurately describes how this technology works to create objects. “Additive” refers to the successive addition of thin layers between 16 to 180 microns or more to create an object.
What is the difference between SLA and SLS?
There are some common denominators, for example, both use a laser to trace out and build individual layers. For SLA a liquid resin is cured, where as in SLS powder is selectively fused together.
Because the sintering temperature does not have to reach the melting point of the material, sintering is often chosen as the shaping process for materials with extremely high melting points such as tungsten and molybdenum. The study of sintering in metallurgy powder-related processes is known as powder metallurgy.
How does direct metal laser sintering work?
To create your 3D print, a laser in the printer melts the powder together. So here’s how it works: A super-thin layer of Aluminum or Titanium powder is spread out by a roller. The print chamber of the 3D printer is then heated up.
The Powder Bed Fusion process includes the following commonly used printing techniques: Direct metal laser sintering (DMLS), Electron beam melting (EBM), Selective heat sintering (SHS), Selective laser melting (SLM) and Selective laser sintering (SLS).
MJP or MultiJet Printing is an inkjet printing process that uses piezo printhead technology to deposit either photocurable plastic resin or casting wax materials layer by layer. MJP is used to build parts, patterns and molds with fine feature detail to address a wide range of applications.
PolyJet is a powerful 3D printing technology that produces smooth, accurate parts, prototypes and tooling. With microscopic layer resolution and accuracy down to 0.1 mm, it can produce thin walls and complex geometries using the widest range of materials available with any technology.
Customer Reviews
Comments
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PA Nylon Powder Glass Filled
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Nylon is one of the most commonly used engineering thermoplastics. It is an outstanding combination of mechanical properties like toughness, low coefficient of friction and good abrasion resistance. It is being an ideal replacement for a wide range of materials from metal to rubber because of its cost.
Glass-Filled Nylon is created by adding powdered glass to the nylon resin or by extruding the plastic with glass fibers. The variants exhibit increased structural, impact strength and rigidity. The inclusion of glass fibers to nylon in various amounts 10%, 20%, 30%, 40% increases tensile strength, stiffness, compressive strength and low thermal expansion coefficient over conventional unfilled grades.
By varying the conditions through the addition of various additives, fillers, lubricants, and colorants during polymerization, the mechanical properties of cast nylon may be altered to suit specific applications. Formulations include molybdenum-disulfide filled, moly and oil-filled (blue), and glass-filled grades. Variants within these nylon grades are available to match specific application demands such as FDA compliance, Internally lubricated, heat stabilized, UV stabilized, anti-static, fire retardant, or impact modified.
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Applications
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Timing sprockets
- Speedometer gears
- Cooling fans
- Wire connectors
- Windshield wiper parts
- Brake fluid reservoirs
- Bearings
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Categories
PA Nylon Powder
[fusion_builder_container hundred_percent=”no” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” overlay_color=”” video_preview_image=”” border_size=”” border_color=”” border_style=”solid” padding_top=”” padding_bottom=”” padding_left=”” padding_right=””][fusion_builder_row][fusion_builder_column type=”1_1″ layout=”1_1″ background_position=”left top” background_color=”” border_size=”” border_color=”” border_style=”solid” border_position=”all” spacing=”yes” background_image=”” background_repeat=”no-repeat” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” margin_top=”0px” margin_bottom=”0px” class=”” id=”” animation_type=”” animation_speed=”0.3″ animation_direction=”left” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” center_content=”no” last=”no” min_height=”” hover_type=”none” link=””][fusion_text]Nylon, in general, is a synthetic thermoplastic material with better weathering properties, sunlight resistance, and a higher melting point. It’s commonly used across various civil and military applications due to its great mechanical properties as well. It can be easily dyed, injection molded and machined, with SLS 3D printing in nylon producing precise, durable, lightweight but porous products. Nylon powder can also be combined with other materials such as glass, carbon fibre or aluminium to form a composite material with improved characteristics such as fire-retardant, toughness and metallic.
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Properties:
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| Property | Value (Nylon PA 12) |
|---|---|
| Tensile Strength | 6,815 psi (46 MPa) |
| Density | 0.034 lb/in3 (0.95 g/cm3) |
| Impact Strength | 0.8 ft-lb/in (43 J/m) |
| Flexural Strength | 6,850 psi (47 MPa) |
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Description
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Nylon is a broad family of synthetic thermoplastics based on aliphatic or semi-aromatic polyamides. It is often used for SLS 3D printing. Prints made from nylon powder have good surface finishes and great mechanical properties. Nylon or Polyamide (PA) has different variations which characterize the number and nature of chains in a material. This influences the properties of objects fabricated from nylon powder like resistance, stiffness, moisture absorption and flexibility. The common types are Nylon 6, Nylon 6/6 and Nylon 12. Another way of improving the material properties for specific applications is blending polyamide with add-ins to produce composite materials such as:
Glass-filled Nylon (PA GF) – compared to pure nylon, PA GF demonstrates better stiffness and higher heat resistance but is less flexible and has a natural (off-white) color. The composite is stable, so prints fit better, they are machinable, can be used for consumer goods and sports items, and perform well with complex parts.
Aluminum-filled Nylon (PA AF) – this composite is made by mixing PA with aluminum powder. As a result, objects have a metallic appearance and rigid structure after being printed. PA AF is easy to machine and post-process, less abrasion resistant, more substantial, has a rougher surface, more heat resistant and rigid.
Carbon Fiber filled Nylon (PA CF) – another composite with carbon fiber; its main advantage is electrostatically dissipative characteristics. PA CF features include resistant to temperature and wear, sturdy, lightweight, and has anthracite shade.
Fire-retardant Nylon – despite nylon and its improved versions being heat resistant, this blend can pass the burn test, which makes it an excellent choice for industries requiring fire-retardant parts. Main features include white color, tough, has good mechanical properties, passes smoke and toxicity tests as well.
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Common uses
- Functional prototypes
- Low-volume rapid manufacturing
- Motorsport and aerospace
- Sport products
- Enclosures and housing
- Connectors and mechanical components
- Medical and biocompatible applications
Advantages
- Nylon powders appear stronger than nylon filaments and demonstrates better fitting, accuracy and wear resistance
- It has greater geometrical possibilities, allowing to build complex parts
- It’s possible to make prints which require jointing with adhesives or machining
- Porous structure allows objects to absorb coatings and dyes easily
Disadvantages
- Uncoated prints suck moisture and dust from the air, change color and degrade over time
- Some variations of material experience disproportional shrinkage while printing or cooling
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Source: Treat Stock
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Categories
Sandstone Powder
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| Short description | Gypsum based powder is combined with binding inks and strengthened with an infiltrant after printing |
| Typical use | Architectural models, figurines, realistic process models |
| Finishes | Full CMYK colour with hardening agent makes for matte finish |
| Technology | CJP, Powder bed and ink jet |
| Minimum wall thickness | 2 mm (0.078 in.) |
| Minimum detail | 0.01 mm (0.004 in.) |
| Clearance | 0.25 mm (0.009 in.) |
| Multiple colour finishes? | Yes |
| Interlocking or enclosed parts? | Yes |
| Heat resistance | Low |
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Full Color Sandstone offers multi-color printing, making it the best material for figurines, architecture, medical models and other applications that require many colors. Although it’s a great material for decorative models, it is not well suited for handling due to its low strength and brittle nature.
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Common Applications:
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Figurines, Architecture, Terrain, Scans, Art Sculptures, Avatars.
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Handling and Care:
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Sandstone is a brittle material that must be handled with care. Exposure to water will cause fading for the Natural finish. However, the Glossy finish will provide some resistance to water and moisture.
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PMMA or polymethyl methacrylate, is a strong, lightweight and transparent thermoplastic. It is commonly known as acrylic. PMMA filament has excellent impact strength that is significantly higher than glass. In addition, it has half the destiny of glass with comparable transparency and UV absorption properties.
There are several important benefits to using PMMA as a 3d printing material. To begin with, it has a high impact resistance which makes it tough and durable. It’s also extremely rigid with very little flexibility. So, if you’re going to need to print an object that will stand up to a certain amount of stress without bending or deforming, then PMMA 3D printer filaments are a strong contender.
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Features:
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- This is an ideal material when you need a hard object, with little flex, with excellent finish quality and clarity.
- PMMA responds very well to post print finishing, such as sanding, drilling or engraving.
- PMMA lends itself perfectly to the process of lost wax casting due to its ability to burn away cleanly without residue.
- Pure resin quality.
- Clear, thermoplastic acrylic;
- Strong, rigid, lightweight, impact resistant;
- Available in several colors, including neutral, red, blue and green;
- Acetone soluble;
- Generally, not food safe;
- PMMA filament temperature prints from 245C to 255C;
- Recommended printing bed temperature from 100C to 120C.
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| Typical Properties | Value |
|---|---|
| Density [50% RH] | 1.19g/cm³ |
| Glass Transition Temperature | ~105°C |
| Melt Flow Rate(2) | 2.8g/10 min |
| Refractive Index B | 1.49 |
| Light Transmittance | 92% |
| Haze | 0.5% |
| Water Absorption [50% RH] | 0.3% |
| Tensile Strength | 10.2kpsi, 70MPa |
| Compressive Strength | 17kpsi, 117MPa |
| Tensile Elongation at Break | 6% |
| Flexural Strength | 14.9kpsi, 103MPa |
| Flexural Modulus | 479kpsi, 3.3GPa |
| Izod Impact Resistance (notched) | 1.8kJ/m² |
| Charpy Impact Resistance (notched) | 2kJ/m² |
| Charpy Impact Resistance (unnotched) | 11kJ/m² |
| Vicat Softening Temperature [50N] | 108°C |
| Heat Distortion Temperature (Tested at 66psi, 0.45MPa) |
103°C |
| Heat Distortion Temperature (Tested at 264psi, 1.82MPa) |
100°C |
| Moulding Shrinkage [50% RH] | 0.2~0.6% |
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HIPS (High Impact Polystyrene) is a dissolvable filament that is frequently used as support material. It acts as a great support material because it is easily removed with Limonene solution, leaving the clean high-quality print that you want behind. HIPS requires no scraping, cutting, or any other method of removal that may cause damage to your prints.
HIPS is short for High Impact Polystyrene and is very similar to ABS. The primary difference is that HIPS uses Limonene as a solvent. This means that you can use HIPS as a support material which can then easily be dissolved by placing your print in Limonene. This is a fantastic alternative to sanding away regular support material which can make your hands sore and leave you feeling frustrated.
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As you can see from the picture above, HIPS allows you to print all sorts of crazy designs that would be otherwise impossible without a dissolving support material.
HIPS is as easy to print with as ABS but is much less likely to warp. HIPS is ideal for printing in conjunction with ABS because it has a similar strength and stiffness profile to ABS which means they complement each other well. It also helps that HIPS and ABS need to be printed around the same temperature. MatterHackers HIPS prints best with the bed between 90-110°C and the extrusion temp around 230°C
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| PROPERTY | VALUE |
|---|---|
| Density | 1.05g/cm-3 |
| Heat Deflection Temperature | 80C |
| Tensile Strength at Yield | 27 MPa |
| Tensile Elongation at break | 55% |
| Flexural Modulus | 39 MPa |
| Flexural Strength | 2280 MPa |
| Notched Izod Impact | 11 J/M2 |
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Categories
Flexible ABS
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ABS (Acrylonitrile Butadiene Styrene) is another commonly used 3D printer material. Best used for making durable parts that need to withstand higher temperatures. In comparison to PLA filament, ABS plastic is less “brittle” and more “ductile.” It can also be post-processed with acetone to provide a glossy finish. When 3D printing with ABS filament, a heated printing surface is recommended, as ABS plastic will contract when cooled leading to warped parts. ABS filament is available in both 1.75mm and 3mm diameter sizes.
ABS Filament Properties:
As a thermoplastic polymer, it can melt and cool without altering its chemical properties. That makes it an interesting 3D printer filament. There are some companies like Zortrax, which have dedicated 3D printers for the material.
- Great mechanical properties: The material is known to be strong, tough and durable. It is also forgiving to scratches, offers good resistance to heat and everyday chemicals. It can endure heat, pressure and stress like no other home 3D printer material, making it a great choice for „wear and tear“ prints. You can try this out yourself: If you move a strain of ABS filament, will distort and bend before breaking. PLA breaks much more easily.
- Great results: It’s quite forgiving, as long as you print with the right settings and a proper temperature management. You can even achieve overhangs of around 45 degrees. If the print succeeds, the results are very convincing.
- Easy to process: Most makers like the material because you can process its surfaces with acetone, glue parts and even file off some material. Lastly, it can be easily painted with acrylic colors.
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| Density | 1.04 g/cc |
| Extrusion Temperature | 210℃ – 250℃ |
| Filament Diameter | 2.85 mm, 1.75mm |
| Tensile Strength | 40 MPa |
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PETG is a variation of the highly popular Polyethylene Terephthalate (with a glycol modification) (PET). PET is one of the most common plastics in the world today and is being used for food containers, water bottles, and even clothing fibres. Its high mechanical strength, resistance to extreme temperatures, and ability to restrict moisture, has made it and its several variations useful for the food industry, as thermal insulation material, or as precursors for engineering resins. As a 3D printing filament, PETG plastic has proven its worth as a durable material that is easy to use. Figuratively speaking, it combines the most useful characteristics of ABS filament (the rigidity and mechanical properties for functional parts) with the ease of printing that PLA filament affords.
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In short this is a really tough material, it’s extremely durable and prints without odour. Once you’ve dialed in the correct print settings, it prints nicely too. Users report similar finish quality to PLA.
Here are the main benefits to printing with this material and common PETG filament properties:
- Very durable, it’s more flexible than PLA or ABS, but also a little softer. You’d have a hard job breaking it in half, so if an ‘unbreakable’ case or enclosure is what you need, PETG trumps pretty much everything (except, Nylon 12).
- It has very low shrinkage, and therefore no warping. Ideal for printing big stuff.
- PETG is also very strong, it’s not brittle but can be scratched more easily than ABS which is harder.
- PETG plastic makes a terrible support structure, because it sticks so well. But because it sticks so well, layer adhesion is fantastic, so prints come out strong.
- It sticks well to the print bed too, so be careful when you’re removing it after printing.
- It has a great chemical resistance, along with alkali, acid and water resistance.
- Odourless when printing.
Typically Polyethylene filament is supplied in a range of translucent colours, and prints with a nice glossy finish.
It makes it ideal for printing anything that needs to be shatterproof or translucent. Many are taking the leap from using PLA or ABS to just using PETG.
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Specifications:
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| Filament Diameter | 1.75 mm, 2.85mm |
| Density | 1.38 g/cm³ |
| Tensile Strength | 2000 MPa |
| Tensile Elongation At Break* | 120-190% |
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