CH4 FUSED DEPOSITION

MODELLING SYSTEMS
The FDM process was developed in 1988 by S.Crump
who founded Stratasys the following year. Since then the
company has produced more than 1000 systems. The
first product ,the 3D MODELER, was introduced by the
company in 1922.

The FDM process works by extruding a thermoplastic

material and depositing it layer-by-layer fusing it to the
layer beneath it, to form a 3D model. FDM creates
functional prototypes using a variety of engineering
materials like ABS, and polycarbonate.
 PROCESS
Step 1 : The Preparation
FDM begins with a 3D CAD file that is oriented in the
appropriate orientation for building the part. The data is then
mathematically sliced into 2D cross-sections (layers) along the
Z-axis.
Step 2 : The Build
The nozzle is heated to melt the plastic filament and is
mounted to a mechanical stage which can be moved in both
horizontal and vertical directions. As the nozzle is moved over
the table in the required geometry, it deposits a thin bead of
extruded plastic to form each layer and create a two-
dimensional cross section of the model.
 PROCESS
The plastic hardens immediately after being squirted from the
nozzle and bonds to the layer below. The platform then
descends where the next layer is extruded upon the previous.
This continues until the model is completed. The entire system
is contained within a chamber which is held at a temperature
just below the melting point of the plastic.

Step 3 : The Completion

Once all the layers are drawn and the model is complete,
the model is then removed from the platform, and the support
structures are removed from the part.
 PROCESS PARAMETERS
FDM 2000 FDM 3000 FDM 8000 Quantum

Build size 254 x 254 x 254 x 254 x 457 x 457 x 600 x 500 x
mm 254 406 609 600

Accuracy +/- 0.127 +/- 0.127 +/- 0.127-0.254 +/- 0.127

mm

Size mm 660x 914 x 660 x 1067 x 1486 x 1905 x 2235 x 1981 x

1067 914 1003 1118
 PROCESS PARAMETERS
Weight 160 160 392 1134
Kg
Power 220-240 VAC 208-240 VAC 220-240 VAC 208-240 VAC
requirements 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz
10A single 10A single 10A single 10A single
phase phase phase phase

Materials ABS (white) ABS (white) ABS ABS

Investment Investment
casting wax casting wax
Elastomer Elastomer
Layer width 0.254 to 2.54 0.254 to 2.54 0.254 to 2.54 0.38 to 0.51
mm mm mm
Layer 0.05 to 0.762 0.05 to 0.762 0.05 to 0.762 0.18 to 0.25
thickness mm mm mm mm
 ADVANTAGES
 True desktop manufacturing system that can be run in office
environment. There is no worry of exposure to toxic fume and
chemicals.
 The process is clean, simple, easy to operate and produces no
waste
 Fast building for bottle like structure or hollow parts
 Material is supplied in spool form which is easy to handle and
can be changed in minute
 Materials used are very cost effective, typical parts cost under
US$20
 A good variety of material is available including colour ABS
and Medical ABS, investment casting wax and elastomer
 Mid range performance/cost RP system and is the best selling
RP system in 1995
 DISADVANTAGES
 Accuracy is relatively low and is difficult to
build parts with complicated details
 Poor strength in vertical direction
 Slow for building a mass part
 APPLICATIONS
 It does not need laser systems, uses relatively
inexpensive binders, and is easy to change
materials. 
 The main difficulties are in controlling
temperature within the growing part, the need
to provide support structures for the growing
model
 The accuracy which is limited to the nozzle
diameter.
 APPLICATIONS
 Limited number of prototypes needed (1-10)
 Concept Models
 Functional testing
 Si3N4 components with good mechanical properties and
microstructure were produced with a filament containing 55 vol %
of the ceramic.  After FDM, green parts were densified by hot
pressing and gave four point bend strengths similar to that of hot
isostatic pressed parts.
 A fine scaled piezoelectric composite structure can be made
consisting of PZT and polymer.  The piezoelectric properties of the
composite are similar or superior to conventionally processed PZT
composites. 
 Composites with controlled composition distribution and a variety
of microstructures can be made by combining filaments of different
compositions.
 Rapid Manufacturing at
BMW
Rapid Manufacturing Jigs and Fixtures with FDM
Rapid prototyping has become a standard practice in product
development. At the BMW AG plant in Regensburg, Germany, FDM
(fused deposition modeling) continues to be an important component
in vehicle design prototyping. But moving beyond prototyping, BMW
is extending the application of FDM to other areas and functions,
including rapid manufacturing.

“BMW has determined that the FDM process can be an alternative

to the conventional metal-cutting manufacturing methods like
milling, turning, and boring.”
Landing Gear Prepared for
Flight