Rapid Prototyping

Fused deposition modeling

(FDM)
 FDM History
• Stratasys was established in 1988, is one of the
oldest producers of prototypers.
• FDM Commercialized since 1991
• The FDM 1000/1500/1600 prototypers were
systematically developed further with larger build
chambers and the process accelerated (FDM
1650/2000/8000), Quantum, Maxum, and the
latest was Fortus 900mc which has the largest
chamber dimension (914x610x914mm)
 Short Description
• FDM means: “Modelling by application of
melted material”
• The FDM Prototyper melts bulk or wire-
shaped plastic material in an heated
nozzle and applied the pasty melted
matter on the model. The layer generation
results from solidification sue to heat
conduction
 How FDM works:
Process starts with a 3D CAD model sliced into thin layers
in Z-axis. These sliced layers are used to drive an extrusion
head of FDM machine. The building material, in the form of
a thin solid filament, is fed from a spool to a movable head
controlled by servomotors. Second filament is fed from
adjacent nozzle for support material, used to give support
for overhanged or cantilever features. The filament reaches
the liquifier head, melts it and then extruded through a
nozzle onto the part surface.
After covering the whole cross section build platform
descends by one layer thickness to lay down the next layer.
Process repeats itself until full 3D part is formed. The
temperature of machine chamber is precisely controlled
below the melting point of the material so that only little
amount of heat is required to melt the filament and on the
other hand part need to be kept cool enough so that the
molten material solidifies upon contact.
How FDM works:
 How FDM works:
3D CAD Design Quicslice / Insight Software
•Orientation the parts > Low support
volume
•Slicing
•Calculation of the geometry
•Calculation extrussion path
•Calculation of the supports

Finishing Process
-Release support material FDM Machine
-Painting, etc
 FDM Applications
• Concept models
– Concept models can accelerate your design process,
getting your products to market faster, while saving
money.
• Functional prototypes
– As your product’s design evolves from concept to
completion, prototypes play an important role in
communicating its form, fit and function. Functional
prototypes allow you to test and make decisions that
have an impact, sometimes dramatic, on the cost to
manufacture your product. Manufacturing tools
 FDM Applications
• Manufacturing tools
– Stratasys machines can reduce manufacturing time
of assembly tools by 50-85%. You can produce jigs,
fixtures, tooling masters and even production
tooling in hours without machining, tooling or
outsourcing.
• End use parts
– Stratasys machines produce low-volume parts that
are tough enough for integration into your final
product without the expense and lead time of
traditional tooling or machining
 FDM Advantages:
• Vast range of thermoplastic materials
• The ability to use various colors in material
• The machine are all suitable for use in office
• High strength
• Cost-effective
• Waterproof
• ABS material
• No post curing.
• Low end, economical machines.
 FDM Disadvantages
• FDM parts have a ribbed appearance because of plastic
is extruded in horizontal layers, which can be easily
sanded and polished to smooth finish.
• Extensive snap and living hinge features could fail due to
process and material limitations.
• FDM could be a slower process for very large build
volume parts subject to part complexity and shape. Thin
wall and shell parts are faster to make than solid builds.
• The extrusion head must continue moving, or else
material bumps up
• Supports material may be required
 FDM work material:
• ABSi
• ABS plus
• ABS M30
• ABS M30i
• PC
• PC-ABS
• PC-ISO
• PPSF
• Ultem 9085
 Stratasys FDM Products n Services:
• Dimension 3D Printer
• Fortus 3D Production machines
• Red eye services
 Dimension 3D Printer
Dimension 3D Printer Applications
– Proof of Concept
– Functional Testing
– Vacuum Forming
– Marketing Tools
– Product Mockups
• Dimension 3D Printer types:
BST 1200es, SST 1200es, Elite, uPrint
and uPrint Plus
 Fortus 3D Production machines
• Fortus 3D Production Systems produce the most
accurate and durable prototypes and parts using
high-performance thermoplastics. And it offers
the largest build size and maximum throughput.
• Parts produced with a Fortus 3D production
system are 30-300% stronger than Stratasys
parts produced with 3D printers, even when
using the same materials. The advanced
technology of Fortus makes the mechanical
properties of the part the most accurate, stable,
and durable.
Fortus sytem types:
FDM sample products
 Reference
• Gebhardt, Andreas (2003) Rapid
Prototyping. Munich: Hansern
• http://www.stratasys.com
• http://www.fortus.com
• http://www.dimensionprinting.com
• http://au.redeyeondemand.com
• http://blog.p2p4u.com/?p=832