Fused Deposition Modelling (FDM) is one of the most widely used 3D printing technologies, known for its simplicity, affordability, and versatility.
This guide will take you through everything you need to know about FDM 3D printing, from the basics to advanced techniques.
Table of Contents
What is FDM?
Fused Deposition Modelling (FDM) is an additive manufacturing process that builds objects layer by layer using thermoplastic materials. It was developed by S. Scott Crump in the late 1980s and commercialized by Stratasys in 1990. In FDM, a plastic filament is fed into a heated nozzle, melted, and then extruded onto a build platform to form layers that solidify to create a 3D object.
How FDM 3D Printing Works?
The process begins with creating a 3D model using CAD (Computer-Aided Design) software. This model is then exported as an STL (stereolithography) file, which is the standard file format for 3D printing.
The STL file is imported into slicing software, which converts the 3D model into thin horizontal layers and generates G-code. The G-code contains instructions for the 3D printer on how to move, extrude the filament, and build the object layer by layer.
The G-code is uploaded to the 3D printer. The printer heats the nozzle and the build platform (if it has a heated bed). The filament is fed into the nozzle, where it is melted and extruded onto the build platform. The printer follows the G-code instructions to build the object layer by layer.
After printing, the object may require some post-processing, such as removing support structures, sanding, or painting, to achieve the desired finish.
Materials
FDM uses a variety of thermoplastic filaments. Some of the most common materials include:
| Material | Properties | Advantages | Disadvantages | Applications |
| PLA (Polylactic Acid) | Biodegradable, easy to print, available in various colors | Ideal for beginners, low warp, good surface finish | Brittle, lower heat resistance | Prototypes, educational models, decorative items |
| ABS (Acrylonitrile Butadiene Styrene) | Strong, durable, heat-resistant | Stronger than PLA, higher temperature resistance | Requires heated bed, emits fumes, warps easily | Functional parts, automotive components, toys |
| PETG (Polyethylene Terephthalate Glycol) | Combines ease of PLA with strength of ABS | Strong, durable, less warping, food safe | Can be stringy, requires fine-tuning | Mechanical parts, containers, protective cases |
| TPU (Thermoplastic Polyurethane) | Flexible, elastic | Rubber-like properties, durable, impact resistant | Requires slow printing speed, can be challenging to print | Phone cases, flexible joints, wearables |
| Nylon | Strong, durable, wear-resistant | High strength, good layer adhesion, flexible | Hygroscopic (absorbs moisture), requires high print temperature | Functional parts, gears, tools, hinges |
Advantages
The printers and filaments are generally more affordable than other 3D printing technologies, making them accessible for hobbyists and professionals alike. Their user-friendly nature and widespread support within the 3D printing community further enhance their appeal.
One of the significant advantages is the variety of materials available, each with unique properties suited to different applications. Additionally, the technology is highly scalable, suitable for both small desktop printers and large industrial machines, offering versatility in various production environments.
Disadvantages
Despite its many advantages, FDM has some drawbacks. The layer-by-layer deposition process can result in visible lines on the printed object, often requiring post-processing to achieve a smooth finish. The strength of parts can be compromised along the layer lines, potentially affecting the structural integrity of the final product. Furthermore, printing can be slower compared to other 3D printing technologies, particularly when producing complex or large objects, which can be a limitation in time-sensitive applications.
Tips for Successful Printing
- Bed Leveling: Ensure the build platform is level for proper adhesion of the first layer.
- Nozzle Temperature: Use the correct nozzle temperature for the filament to avoid clogs and ensure proper extrusion.
- Bed Adhesion: Use adhesives like glue stick, blue painter’s tape, or specialized bed surfaces to improve adhesion and prevent warping.
- Cooling: Use cooling fans appropriately, especially for PLA, to improve print quality and prevent deformation.
- Support Structures: Use support structures for overhangs and complex geometries, and remove them carefully after printing.
- Maintenance: Regularly clean and maintain your printer, including the nozzle, bed, and extruder, for consistent performance.
Applications
FDM is used in a variety of applications across different industries. In prototyping, it enables the rapid development of design concepts and functional prototypes, allowing for iterative testing and refinement. In education, this technology is a valuable tool for teaching students about 3D printing and engineering concepts, providing hands-on learning opportunities.
The manufacturing sector benefits from this technology by using it to create jigs, fixtures, and end-use parts, streamlining production processes and reducing costs. Artists and designers utilize this technology to produce sculptures, models, and customized items, taking advantage of its ability to create complex and unique geometries. In the medical field, this technology is employed to print anatomical models, custom prosthetics, and medical devices, enhancing patient care and enabling personalized medical solutions.
FDM 3D Printer
Here are 5 popular FDM 3D printers in 2024:
- Bambu Lab P1S – Best Overall: This feature-rich printer offers exceptional print quality, super fast speeds, and a user-friendly design. It’s ideal for both beginners and experienced makers.
- Creality Ender 3 V3 SE – Best Budget FDM Printer: A perennial favorite, the Ender 3 V3 SE is a great option for those looking for a reliable and affordable printer. It’s easy to set up and use, making it a good choice for beginners.
- Elegoo Neptune 4 Pro – Best Beginner FDM Printer: This user-friendly printer is perfect for those new to 3D printing. It comes with a number of features that make it easy to get started, such as auto-leveling and a quiet operation.
- Sovol SV08 – Fastest FDM Printer: If speed is your priority, then the Sovol SV08 is the printer for you. It can print at speeds of up to 300mm/s, making it one of the fastest FDM printers on the market.
- Original Prusa XL – Best Multicolor FDM Printer: This high-end printer is capable of printing in up to five colors at once. It’s a great option for those who need to create complex and colorful prints.
Conclusion
FDM 3D printing is a versatile and accessible technology that has revolutionized manufacturing, prototyping, and design. By understanding the basics of FDM, selecting the right materials, and following best practices, you can achieve successful prints and bring your ideas to life. Whether you are a hobbyist, an educator, or a professional, FDM offers endless possibilities for creativity and innovation.
