OVERVIEW

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.

When part durability is required, FDM can produce parts using production materials.

 

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. 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.

 

APPLICATIONS

• Limited number of prototypes needed (1-10)
• Concept Models
• Functional testing