Lecture 8

Fused Deposition Modeling (FDM)

Fused Filament Fabrication (FFF)
FUSED DEPOSITION MODELING
FDM
FUSED wasDEPOSITION
developed by Stratasys Inc., which
MODELIND (FDM)sold
its first machine in 1990.

S. Scott Crump (born Steven Scott Crump) is the self-proclaimed inventor of

fused deposition modeling (FDM) and co-founder of Stratasys, Ltd.
Crump invented and patented FDM technology in 1989 with his wife and
Stratasys co-founder Lisa Crump. He is currently the Chairman of the Board of
Directors of Stratasys, which produces additive manufacturing machines for
direct digital manufacturing (a.k.a. rapid manufacturing); these machines are
popularly called “3D printers.” He took the manufacturing company public in
1994 (Nasdaq: SSYS). He also runs Fortus, RedEye on Demand, and Dimension
Printing – business units of Stratasys.
 FUSED DEPOSITION MODELIND (FDM)

Crump managed the early work on another innovation

used by FDM machines, the ABS plastic filament, which
allows engineers to formulate fully functional parts that
have up to 75% of the strength of an actual molded part.
In addition, Crump is responsible for other innovations
including: Breakaway Support System (BASS), WaterWorks
Support System, the coupling to the CAD/CAM industry
for CNC tool path software, a baffled oven for high
temperature build environments and a benchtop 3D
Printer (Dimension)
 FUSED DEPOSITION MODELIND (FDM)
• Synonyms:

• Fused Filament Fabrication (FFF),

• Fused Layer Modeling/Manufacturing, (FLM).
 FUSED DEPOSITION MODELIND (FDM)

Fused-Deposition Modeling Fused-deposition

modeling (FDM) is an RP process in which a
filament of wax or polymer is extruded onto the
existing part surface from a workhead to
complete each new layer.
FUSED DEPOSITION MODELIND (FDM)
 FUSED DEPOSITION MODELIND (FDM)
The workhead is controlled in the x-y plane during each layer and
then moves up by a distance equal to one layer in the z-direction.
The starting material is a solid filament with typical diameter ¼
1.25 mm (0.050 in) fed from a spool into the workhead that
heats the material to about 0.5oC (1F) above its melting point
before extruding it onto the part surface.
 FUSED DEPOSITION MODELIND (FDM)
The extrudate is solidified and cold welded to the cooler part
surface in about 0.1 second. The part is fabricated from the base
up, using a layer-by-layer procedure similar to other RP systems.
 FUSED DEPOSITION MODELIND (FDM)
The starting data is a CAD geometric model that is processed by
Stratasys’s software modules QuickSlice; and SupportWorkTM.
QuickSlice; is used to slice the model into layers, and
SupportWork TM is used to generate any support structures that
are required during the build process.
 FUSED DEPOSITION MODELIND (FDM)
If supports are needed, a dual extrusion head and a different
material is used to create the supports. The second material is
designed to readily be separated from the primary modeling
material.
 FUSED DEPOSITION MODELIND (FDM)
The slice (layer) thickness can be set anywhere from 0.05 to
0.75mm(0.002 to 0.030 in).

About 400mm of filament material can be deposited per second

by the extrusion workhead in widths (called the road width) that
can be set between 0.25 and 2.5 mm (0.010 to 0.100 in).
 FUSED DEPOSITION MODELIND (FDM)
Starting materials are wax and several polymers, including ABS,
polyamide, polyethylene, and polypropylene. These materials are
nontoxic, allowing the FDM machine to be set up in an office
environment.
 Filament material
FUSED DEPOSITION MODELIND (FDM)
• “Standard”materials:
– Poly-Lactic-Acid (PLA) (soft and hard)
– Acrylonitril‐Butadiene‐Stirene (ABS)

• “Experimental” materials:
– Nylon
– Polycarbonate (PC)
Examples of FDM systems
Examples of FDM systems
dr Adrian Bowyer – founder of RepRap
 Idea of RepRap
RepRap = replicating rapid prototyper
develop a low-cost 3D printer that can print most of its own
components
All of the designs produced by the project are released under
a free software license
Timeline (history)
 Examples of RepRap printers
As an open source project designers are free to make modifications. That’s why there is variety of
different types of such printers. Below are some examples:

• Hangprinter
• RepRap Snappy
• Prusa i3
• Kossel
 RepRap Snappy
The RepRap Snappy is able to create 73% of its own parts by volume with
a design that eliminates as many of the non 3D printed parts as possible
including belts and bearings which are replaced with a rack and pinion
system. The name Snappy comes from the use of snap fit connectors used
on the small printed parts to construct larger pieces.
 Hangprinter
All parts of the Hangprinter are contained within a single unit
which uses cables to suspend the printer within a room,
allowing it to create extremely large objects over 4 meters tall.
The Hangprinter uses relatively low cost parts and can be
constructed for around $250 USD
 Prusa i3
The most used 3D printer in the world (2016). The Prusa i3's comparable low cost and ease
of construction and modification has made it popular in education and with hobbyists and
professionals. Depending on the hot end and heated bed installed, the Prusa i3 is capable
of printing many materials including Acrylonitrile butadiene styrene (ABS), polylactic acid
(PLA), high impact polystyrene (HIPS), polyetilene (PET), different flexible filaments (FLEX),
polypropylene (PP) and nylon.
 Kossel
Kossel is a parametric delta robot 3D printer, built in 2012 by Johann in Seattle, USA, based on his
Rostock prototype.

Design Goals:
• Zero backlash.
• Type: Delta printer
• Speed: 320 mm/s in all 3 directions.
• Resolution: 100 steps/mm in all 3 directions.
• Repeatability: better than 0.03 mm (30 micron)
• Build volume: cylindrical, 170mm diameter, 240mm height.
• Footprint: triangle, 300 mm width (240mm OpenBeam + printed corners).
• Frame height: 600 mm.
• Print surface: unheated round glass, doesn't move.
• Mass of end effector with hotend: less than 50 grams.
• Simplicity: fewer than 200 parts.
• Hardware cost: less than $600 USD.
• Fully automatic print surface level calibration (autoleveling).
 Popularity
Advantages:
• Customisation and ability to improve quality, adapt and modify.
• Fanatical support community rather than dependence on a single
company
• Cost. One can be made from cheap, proven and familiar electronics.

"...the unavoidable conclusion from

this study is that the RepRap is an
economically attractive investment
for the average US household
already."
 Constraints
For now not all elemets of printer (that are necessary to buid itself) can be
produced by printer, for example sensors, motors and electronics. But the
aim is to change that situation and gradually increase percentage of parts
created by printer (currently the RepRap Snappy is able to create 73% of
its own parts by volume). There are some studies concerning problem of
printing electronics systems that can be used as microcontrollers.

Disadvantages:
• Fiddly
• very sensitive to many
parts that can cause a
failed print
• not plug and play

A Huxley RepRap 3D printer that

has printed out its own parts.
 A compromise between money and time
The cheapest way to have a 3D printer is to build it on your own. With Chinese parts, bargains, and reused motors, it can
cost you even under $100. More often it is about $300-$600. But completing the set of parts can take months (or even
years if you are very lazy!). And you will need some technical skills to know how to build it, even with great RepRap-
community support. In the end, you will have to build your own firmware configuration (a bit of programming skills will
be needed).

It’s still not very expensive to buy one of the RepRap kits – currently prices start from about $180 up to $1000.
But you need to remember that a lower price means lower quality. You will still need some technical skills, but
the instructions included will make it a little easier. And you will be ready to use firmware build.

With about $400-$1200, you can get an assembled RepRap – you do not have to know how to build it, but you still have to
know how to repair it, calibrate it, and adjust its printing parameters. With $1200 or more, you can get a working
commercial printer – just plug in and play. No skills needed, no know-how to gain. Just connect it to the mains, turn it on,
and feed in some material (you will probably get samples with it).
 Sources
• https://en.wikipedia.org/wiki/RepRap_project
• Moilanen, J. & Vadén, T.: Manufacturing in motion: first survey
on the 3D printing community
• B.T. Wittbrodt et al., Life-cycle economic analysis of distributed
manufacturing with open-source 3-D printers
• http://reprap.org/
• http://qmentis.com/3d-printing/reprap/beginners-guide-to-
reprap/
• https://www.3dnatives.com/en/reprap-3d-printer-301020174/
• http://enacademic.com/dic.nsf/enwiki/959081
 What is FDM?
 constructs three-dimensional objects

 building models layer by layer

 head with temprature-controlled extrusion nozzles

 support structure is created where needed

 materials filament unwound from a coil

 The Invention of FDM Technology

Stratasys founder Scott Crump

invented FDM Technology more
than 20 years ago, and Stratasys
has continued to lead the 3D
printing revolution ever since,
developing a range of systems that
appeal to large manufacturers,
designers, engineers, educators
and other professionals.
 What kind of materials are used in
FDM method?
Colors of materials: Materials:
 white,  ABSplus
 black,
 ABSi
 red,
 ABS-M30
 green,
 ABS-M30i
 blue,
 ABS-ESD7
 gray,
 yellow.
 PC
 PC-ABS
 PC-ISO
 PPSF/PPSU
 ULTEM 9085
 FDM technical specifications
Precision made models
Standard lead time:
 the most accurate machines of
 4-5 days
RP

Layer thickness:  possibility of obtaining models

 0.13 - 0.25mm (for ABS) with wall thickness of only 0.6
mm.
 0.18 - 0.25mm (for ABSi)  the minimum diameter of the
rollers are 0.75 mm
 0.18 - 0.25mm (for PC)
 mechanical properties of models
 0.25mm (for PPSU) are comparable with elements
which received by injection
 Application FDM

 prototypes and machine parts (housing, switches, brackets),

 prototypes of glass packaging and plastic (bottles, jars),
 spare parts of machines,
 prototypes cooperating mechanisms,
 strength tests, tests, type approvals,
 tests of functionality, shape, fit testing, strength analysis,
 ergonomics test,
 construction of functional elements of technical device e.g.
housing, turbine, prototyping of complex device.
 What tolerances are Stratasys FDM
3D Printers capable of holding?
Tolerances are a function of the system producing the part and the
overall size of the part.

For the Mojo, Dimension, and uPrint systems there is no standard

tolerance. Dimensional accuracy will vary based upon part size,
geometry, and orientation. These systems are designed to produce
concept 3D models which do not typically require accuracy down to
a few thousandths of an inch.

The Fortus 360mc and 400mc large and small systems deliver an
accuracy of ± 0.005 inch or ± 0.0015 in./ in. (± 0.127 mm or ±
0.0015 mm/ mm), whichever is greater.

The Fortus 900mc parts are produced within an accuracy of ±

0.0035 inch or ± 0.0015 in./in. (± 0.089 mm or ± 0.0015 mm/ mm),
whichever is greater.
Examples of FDM models
 What are the advantages of modeling FDM?
 high strength printed prototypes,

 model can be printed in standard colors: white, blue, yellow, green, black,
red and gray;

 short time producing fully functional prototypes do not require additional

treatment such curing, grinding

 FDM prototype technology allows you to test the model, preventing costly
mistakes,

 accurate and functional prototypes at the lowest possible cost

performance;

 the complete mapping of parameters of thermoplastics (ABS, PC);

 the complete mapping of parameters of thermoplastics (ABS, PC);

 the possibility of applying a variety of galvanic coatings (chrome);

 tightness and resistance to the action of water

Industries in which FDM technology is used
 Aerospace
 Commercial Products
 Dental
 Architecture
 Consumer Products
 Education
 Automotive
 Defense
 Medical