Fused Deposition Modeling (FDM)

Fused Deposition Modeling (FDM) is one of the most widely used additive manufacturing process for
fabricating prototypes and functional parts in common engineering thermoplastics. The process is based
on the extrusion of heated feedstock plastic filaments through a nozzle tip to deposit layers onto a
platform to build parts layer by layer directly from a computer-aided design (CAD) model. By utilizing
the FDM system, engineers can convert their conceptual models or part design of any complexity into
accurate physical models readily within a normal office environment. The simplicity, reliability,
and affordability of the FDM process have made the additive manufacturing technology widely
recognized and adopted by industry, academia, and consumers. The FDM process has also been widely
used by research and development sectors to improve the process, develop new materials, and apply the
FDM systems in a wide range of engineering applications in biomedical engineering, tissue engineering
(TE), and tooling. This is one of the earliest types of AM processes, originally developed and marketed
by Stratasys Company in United States during the early 1990s.

In general, there are four stages in part fabrication by FDM technology

1. CAD modeling;

2. Preprocessing on FDM software;

3. Part building on FDM machine;

4. Support removal of fabricated parts.

A FDM machine consists of a movable head which deposits a thread of molten material onto a substrate.
The build material is heated to 0.5°C above its melting point so that it solidifies about 0.1 s after extrusion
and cold welds to the previous layers. Figure 1 shows the schematic of the basic FDM process and
liquefier head with model material flow. Process parameters to be taken into consideration are the
necessity for a steady nozzle speed and material extrusion rate, the addition of a support structure for
overhanging parts, and the speed of the liquefier head which affects the overall layer thickness. More
recent FDM systems include two nozzles, one for the part material and one for the support material. The
latter is cheaper and breaks away from the prototype without impairing its surface. It is also possible to
create horizontal supports to minimize material usage and build time.

Advantages

1. Simplicity, Safety, and Ease of Use: FDM machines are safe, reliable, easy to use, and office friendly.
There is no toxic material, powder handling, intense heat, or laser involved. Parts can be handled almost
immediately after fabrication. Except for support removal, almost no post-processing is required.
Maintenance cost is very low. Machines can run unattended for hours.

2. No Material Wastage: Being an extrusion-based process, only the required amount of filament
material is used to create the part and to create the supports. The FDM software also provides an estimate
of the model material required and build time before the actual process starts.

3. Variety of Build Styles: FDM process software allows extensive possibilities of tool path build styles
used in each layer by altering appropriate process variables such as raster width, fill pattern, raster angle,
and air gaps. This enables users to create internally filled solid parts or porous parts of a variety of
internal architecture.

4. Variety of Engineering Polymers: The Stratasys FDM systems offer a variety of engineering
materials with high strength and good mechanical properties. ABS and PC are common engineering
materials. Hence, parts made in these materials are good for functional testing. Solid parts made in these
materials by FDM machines are highly appropriate for intended industrial application.

5. Ease of Support Removal: Normally, supports can easily be snapped off by hand from models.
Stratasys also provides a WaterWorks soluble support system or Break Away support system, which
allows easy removal by hand or easy removal in a water solution.

Disadvantages

1. Surface Finish and Accuracy: Surface finish of the parts, which is inferior to that, produced using
SLA. This is because the resolution of the process is lower as this is dictated by the filament thickness.

2. Feedstock Filaments: FDM material needs to be made in filament form of required diameter
(approximately 1.7 mm) and required mechanical and rheological properties. Any new material to be
introduced must also meet these requirements.

3. Anisotropic Properties: As the parts are built by depositing extruded roads, the mechanical properties
of the parts are not the same in all directions. Orientation of the part on the build table also affects the
mechanical strength of the part in different build directions.
Applications

1. The creation of concept models used in early stages of product development.

2. The creation of functional prototypes for testing purposes. These prototypes allow to test in real world
environments and make decisions that have a dramatic effect on the cost to manufacture to the product.

3. Fabrication of end-use parts. Without the expense and lead time of traditional tooling or machining,
FDM produces end-use parts tough enough for integration into the final product. Ideal for building small
quantities of parts while waiting for tooling, FDM Technology makes it possible to get the products to
market faster.

4. Fabrication of manufacturing tools. FDM reduces the time it takes to create manufacturing tools by up
to 85%. It produces manufacturing tools such as jigs and fixtures, tooling masters and production tooling
in hours without expensive machining or tooling.