MALLABHUM INSTITUTE OF TECHNOLOGY

(Approved by AICTE & Affiliated to MAKAUT)

Fused Deposition Modelling

Presented by
KAZI WASIM AKTAR

University Roll No.- 15800721051

Year: 4th Semester: 8th
Subject: 3D Printing and Design (PE-ME 802F)
Academic Year: 2023-2024
 TITLE

Fused Deposition Modelling

 Introduction
Fused Deposition Modeling (FDM) is a revolutionary additive manufacturing technology that has
transformed the landscape of 3D printing. Developed by Scott Crump in the late 1980s and
trademarked by Stratasys, FDM has become one of the most widely adopted methods for creating
three-dimensional objects layer by layer.
At its core, FDM relies on a straightforward yet ingenious process. The technology employs a
thermoplastic filament, typically composed of materials such as PLA or ABS, which is fed through a
heated extrusion nozzle. As the filament reaches its melting point, it becomes malleable and is
meticulously deposited layer upon layer to construct a tangible, three-dimensional structure. The
entire process is orchestrated by a computer-controlled system that interprets a digital 3D model,
guiding the precise movements of the extrusion nozzle and the build platform.
One of the key advantages of FDM is its versatility. The technology accommodates a variety of
thermoplastic materials, enabling the creation of objects with diverse properties and applications.
Additionally, FDM is renowned for its cost-effectiveness and user-friendly operation, making it
accessible to a broad range of users, from hobbyists to industrial manufacturers.
 Working Principle of Fused Deposition Modelling
1.Digital Model Creation:
1. A 3D model of the desired object is created using computer-aided design (CAD) software. This digital
model is typically saved in a standard file format such as STL (stereolithography) or OBJ (object).
2.Slicing the Model:
1. The digital 3D model is sliced into thin, horizontal cross-sectional layers using slicing software. Each layer
represents a physical cross-section of the object.
3.Printing Setup:
1. The sliced layers are sent to the FDM 3D printer, and the user specifies printing parameters such as layer
height, print speed, and temperature.
2. The 3D printer is equipped with a heated build platform and an extrusion nozzle. The build platform
provides a stable surface for the object to be printed, and the extrusion nozzle is responsible for melting
and depositing the filament.
4.Filament Feeding:
1. A thermoplastic filament, often made of materials like PLA or ABS, is loaded onto a spool. The filament
is then fed into the heated extrusion nozzle.
5.Heating and Extrusion:
1. The extrusion nozzle heats the filament to its melting point. Once melted, the material becomes semi-
liquid and is ready for deposition.
2. The nozzle moves along the X, Y, and Z axes as dictated by the instructions from the slicing software,
and it deposits the melted filament in precise paths, layer by layer.
 Components of Fused Deposition Modelling
1.Frame:
1. The frame provides the structural support for the entire 3D printer. It holds all the components in place
and ensures stability during the printing process.
2.Build Platform:
1. The build platform is the surface on which the 3D object is constructed layer by layer. It can be heated
to help with adhesion and to reduce warping of the printed layers.
3.Extruder/Extrusion Nozzle:
1. The extruder is responsible for feeding the thermoplastic filament into the system and melting it. The
extrusion nozzle, located at the tip of the extruder, deposits the melted material onto the build platform
or previously printed layers.
4.Thermoplastic Filament:
1. FDM printers use spools of thermoplastic filament as the raw material for 3D printing. Common
filament materials include PLA (polylactic acid), ABS (acrylonitrile butadiene styrene), PETG
(polyethylene terephthalate glycol), and more.
5.Filament Drive Gear:
1. The filament drive gear is a toothed wheel that grips and feeds the filament into the extruder. It ensures
a consistent and controlled flow of filament.
6.Heating Element:
1. The heating element, often located within the extruder, heats the thermoplastic filament to its melting
point. This is a crucial step in the FDM process as it allows the material to become molten and ready
for extrusion.
1.Cooling Fans:
1. Cooling fans are used to rapidly cool the freshly deposited layers of melted filament, promoting
solidification and maintaining the structural integrity of the printed object.
2.Stepper Motors:
1. Stepper motors control the movement of the extruder and the build platform along the X, Y, and Z axes.
Precise control of these motors is essential for accurate layer deposition.
3.Print Bed Leveling System:
1. This system ensures that the build platform is perfectly level, which is crucial for achieving uniform layer
adhesion and preventing printing issues.
4.Controller Board:
1. The controller board is the brain of the 3D printer. It interprets the G-code generated by slicing software,
controlling the movements of the motors, the temperature of the extruder, and other aspects of the printing
process.
5.Display Screen and User Interface:
1. The display screen and user interface allow users to control and monitor the 3D printer. Users can start or
stop prints, adjust settings, and monitor the progress of the print job.

These components work together seamlessly to execute the FDM 3D printing process, enabling the creation of
intricate and customized three-dimensional objects.
 Applications of FDM
1.Rapid Prototyping:
1. FDM is widely used for rapid prototyping in product development. It allows designers and engineers to
quickly iterate and test designs before committing to expensive production processes.
2.Product Development:
1. FDM enables the creation of functional prototypes for testing and validation in the early stages of
product development. This helps identify design flaws, improve functionality, and reduce time-to-
market.
3.Customized Manufacturing:
1. FDM is suitable for producing customized and low-volume parts, making it ideal for manufacturing
products tailored to specific customer requirements. This is particularly valuable in industries such as
healthcare (custom implants) and consumer goods (personalized accessories).
4.Aerospace Industry:
1. FDM is used in aerospace for producing lightweight components, prototypes, and tooling. The ability
to create complex geometries and lightweight structures makes it valuable for aircraft design and
manufacturing.
5.Automotive Prototyping:
1. Automotive engineers use FDM to create prototypes of components such as interior parts, brackets,
and functional prototypes of vehicle parts. It allows for quick validation of designs and fitment.
 Advantages of FDM
1.Cost-Effective:
1. FDM is generally considered a cost-effective 3D printing technology. The equipment and materials are
relatively affordable, making it accessible for small businesses, educational institutions, and hobbyists.
2.Material Variety:
1. FDM supports a wide range of thermoplastic materials, including PLA, ABS, PETG, TPU, and more. This
versatility allows users to choose materials based on their specific requirements, such as strength, flexibility,
or heat resistance.
3.Ease of Use:
1. FDM printers are known for their user-friendly operation. The technology is relatively simple, making it
accessible to individuals with varying levels of expertise in 3D printing.
4.Rapid Prototyping:
1. FDM is excellent for rapid prototyping, enabling designers and engineers to quickly iterate on designs and
test concepts. This accelerates the product development process and reduces time-to-market.
5.Customization:
1. FDM excels at producing customized, one-off parts. It is ideal for creating personalized items, prototypes,
and small batches of unique products tailored to specific requirements.
 Limitations of FDM
1.Layer Resolution:
1. FDM typically produces visible layer lines on the printed object. Achieving very fine layer resolution may
require specialized equipment and can impact the speed of printing.
2.Surface Finish:
1. The surface finish of FDM-printed objects is often not as smooth as those produced by other 3D printing
technologies, such as Stereolithography (SLA) or PolyJet. Post-processing may be needed to improve surface
aesthetics.
3.Material Limitations:
1. FDM is limited to using thermoplastic materials, which may not offer the same range of properties as
materials used in other 3D printing methods. While there is a variety of filaments available, they may have
limitations in terms of strength, flexibility, or heat resistance.
4.Support Structures:
1. Printing overhangs and complex geometries often requires support structures. While these supports are
necessary for successful prints, they can be time-consuming to remove and may leave visible marks on the
finished object.
5.Strength Anisotropy:
1. The strength of FDM-printed parts can vary along different axes due to the layer-by-layer construction. Parts
are typically stronger along the vertical (Z) axis than along the horizontal (X and Y) axes.
 Conclusion of FDM
In conclusion, Fused Deposition Modeling (FDM) stands as a transformative and accessible 3D printing
technology with a multitude of applications across diverse industries. Its advantages, such as cost-effectiveness,
versatility, and ease of use, have made it a popular choice for prototyping, product development, and small-
scale manufacturing.
FDM's ability to rapidly produce functional prototypes enables designers and engineers to iterate quickly,
reducing time-to-market and fostering innovation. The technology's adaptability to various thermoplastic
materials allows for customization and the production of end-use parts with specific properties.
However, FDM is not without its limitations. Challenges such as visible layer lines, surface finish issues, and
material constraints must be considered. Additionally, the technology may not be suitable for applications
requiring extremely high precision or intricate details.
Despite these limitations, FDM remains a crucial player in the 3D printing landscape, providing a cost-
effective and accessible means for bringing digital designs into the physical realm. As technology advances,
ongoing research and development may address current limitations, further enhancing the capabilities and
expanding the applications of FDM in the future. Whether in educational settings, prototyping labs, or
production floors, Fused Deposition Modeling continues to empower creativity, innovation, and
customization in the world of additive manufacturing.