Fused deposition modeling
Encyclopedia
Fused deposition modeling (FDM) is an additive manufacturing technology commonly used for modeling, prototyping, and production applications. The technology was developed by S. Scott Crump
in the late 1980s and was commercialized in 1990.
, which processes an STL file (stereolithography file format) in minutes, mathematically slicing and orienting the model for the build process. If required, support structures are automatically generated. The machine dispenses two materials – one for the model and one for a disposable support structure.
The thermoplastics are liquefied and deposited by an extrusion head, which follows a tool-path defined by the CAD file. The materials are deposited in layers as fine as 0.04 mm (0.0016") thick, and the part is built from the bottom up – one layer at a time.
FDM works on an "additive" principle by laying down material in layers. A plastic filament or metal wire is unwound from a coil and supplies material to an extrusion
nozzle which can turn the flow on and off. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism, directly controlled by a computer-aided manufacturing
(CAM) software package. The model or part is produced by extruding small beads of thermoplastic
material to form layers as the material hardens immediately after extrusion from the nozzle. Stepper motors or servo motors are typically employed to move the extrusion head.
Several materials are available with different trade-offs between strength and temperature properties. As well as acrylonitrile butadiene styrene
(ABS) polymer, polycarbonate
s, polycaprolactone
, polyphenylsulfones and waxes. A "water-soluble" material can be used for making temporary supports while manufacturing is in progress, this soluble support material is quickly dissolved with specialized mechanical agitation equipment utilizing a precisely heated sodium hydroxide solution.
The term fused deposition modeling and its abbreviation to FDM are trademarked by Stratasys Inc. The exactly equivalent term, fused filament fabrication (FFF), was coined by the members of the RepRap project to give a phrase that would be legally unconstrained in its use.
, is used for prototyping and rapid manufacturing. Rapid prototyping facilitates iterative testing, and for very short runs, rapid manufacturing can be a relatively inexpensive alternative. .
FDM uses the thermoplastics ABS, ABSi, polyphenylsulfone (PPSF), polycarbonate
(PC), and Ultem 9085, among others. These materials are used for their heat resistance properties. Ultem 9085 also exhibits fire retardancy making it suitable for aerospace and aviation applications.
FDM is also used in prototyping scaffolds for medical tissue engineering applications.
S. Scott Crump
S. Scott Crump is the inventor of fused deposition modeling and co-founder of Stratasys, Inc. Crump invented and patented FDM technology in 1989 with his wife and Stratasys co-founder Lisa Crump. He is currently the CEO and president of Stratasys, which produces additive manufacturing machines...
in the late 1980s and was commercialized in 1990.
Process
FDM begins with a software process, developed by StratasysStratasys
Stratasys, Inc. , founded by S. Scott Crump and his wife Lisa Crump, is a company that manufactures additive fabrication machines for direct digital manufacturing , 3D printing and rapid prototyping...
, which processes an STL file (stereolithography file format) in minutes, mathematically slicing and orienting the model for the build process. If required, support structures are automatically generated. The machine dispenses two materials – one for the model and one for a disposable support structure.
The thermoplastics are liquefied and deposited by an extrusion head, which follows a tool-path defined by the CAD file. The materials are deposited in layers as fine as 0.04 mm (0.0016") thick, and the part is built from the bottom up – one layer at a time.
FDM works on an "additive" principle by laying down material in layers. A plastic filament or metal wire is unwound from a coil and supplies material to an extrusion
Extrusion
Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section...
nozzle which can turn the flow on and off. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism, directly controlled by a computer-aided manufacturing
Computer-aided manufacturing
Computer-aided manufacturing is the use of computer software to control machine tools and related machinery in the manufacturing of workpieces. This is not the only definition for CAM, but it is the most common; CAM may also refer to the use of a computer to assist in all operations of a...
(CAM) software package. The model or part is produced by extruding small beads of thermoplastic
Thermoplastic
Thermoplastic, also known as a thermosoftening plastic, is a polymer that turns to a liquid when heated and freezes to a very glassy state when cooled sufficiently...
material to form layers as the material hardens immediately after extrusion from the nozzle. Stepper motors or servo motors are typically employed to move the extrusion head.
Several materials are available with different trade-offs between strength and temperature properties. As well as acrylonitrile butadiene styrene
Acrylonitrile butadiene styrene
Acrylonitrile butadiene styrene is a common thermoplastic. Its melting point is approximately 105 °C ....
(ABS) polymer, polycarbonate
Polycarbonate
PolycarbonatePhysical PropertiesDensity 1.20–1.22 g/cm3Abbe number 34.0Refractive index 1.584–1.586FlammabilityV0-V2Limiting oxygen index25–27%Water absorption – Equilibrium0.16–0.35%Water absorption – over 24 hours0.1%...
s, polycaprolactone
Polycaprolactone
Polycaprolactone is a biodegradable polyester with a low melting point of around 60°C and a glass transition temperature of about −60°C. PCL is prepared by ring opening polymerization of ε-caprolactone using a catalyst such as stannous octoate. Recently a wide range of catalysts for the ring...
, polyphenylsulfones and waxes. A "water-soluble" material can be used for making temporary supports while manufacturing is in progress, this soluble support material is quickly dissolved with specialized mechanical agitation equipment utilizing a precisely heated sodium hydroxide solution.
The term fused deposition modeling and its abbreviation to FDM are trademarked by Stratasys Inc. The exactly equivalent term, fused filament fabrication (FFF), was coined by the members of the RepRap project to give a phrase that would be legally unconstrained in its use.
Commercial applications
FDM, a prominent form of rapid prototypingRapid prototyping
Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. The first techniques for rapid prototyping became available in the late 1980s and were used to produce models and prototype parts. Today, they are used for a much wider range of applications...
, is used for prototyping and rapid manufacturing. Rapid prototyping facilitates iterative testing, and for very short runs, rapid manufacturing can be a relatively inexpensive alternative. .
FDM uses the thermoplastics ABS, ABSi, polyphenylsulfone (PPSF), polycarbonate
Polycarbonate
PolycarbonatePhysical PropertiesDensity 1.20–1.22 g/cm3Abbe number 34.0Refractive index 1.584–1.586FlammabilityV0-V2Limiting oxygen index25–27%Water absorption – Equilibrium0.16–0.35%Water absorption – over 24 hours0.1%...
(PC), and Ultem 9085, among others. These materials are used for their heat resistance properties. Ultem 9085 also exhibits fire retardancy making it suitable for aerospace and aviation applications.
FDM is also used in prototyping scaffolds for medical tissue engineering applications.
See also
- 3D printing3D printing3D printing is a form of additive manufacturing technology where a three dimensional object is created by laying down successive layers of material. 3D printers are generally faster, more affordable, and easier to use than other additive manufacturing technologies. However, the term 3D printing is...
- Additive manufacturingAdditive manufacturingAdditive manufacturing is defined by ASTM as the "process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies, such as traditional machining...
- Desktop manufacturing
- Digital fabricator
- Direct digital manufacturing
- Direct metal laser sinteringDirect metal laser sinteringDirect metal laser sintering is an additive metal fabrication technology developed by EOS out of Munich, Germany, sometimes also referred to by the terms selective laser sintering or selective laser melting . The process involves use of a 3D CAD model whereby a .stl file is created and sent to...
- Fab labFab labA fab lab is a small-scale workshop offering digital fabrication.A fab lab is generally equipped with an array of flexible computer controlled tools that cover several different length scales and various materials, with the aim to make "almost anything"...
- Instant manufacturing
- MakerBot IndustriesMakerBot IndustriesMakerBot Industries is a Brooklyn, New York-based company founded in January 2009 by Bre Pettis, Adam Mayer, and Zach "Hoeken" Smith producing open source hardware, specifically 3D printers...
- Rapid manufacturing
- Rapid prototypingRapid prototypingRapid prototyping is the automatic construction of physical objects using additive manufacturing technology. The first techniques for rapid prototyping became available in the late 1980s and were used to produce models and prototype parts. Today, they are used for a much wider range of applications...
- RepRap ProjectRepRap ProjectThe RepRap project is an initiative to develop a 3D printer that can print most of its own components...
- Selective laser sinteringSelective laser sinteringSelective laser sintering is an additive manufacturing technique that uses a high power laser to fuse small particles of plastic, metal , ceramic, or glass powders into a mass that has a desired 3-dimensional shape...
- Solid freeform fabrication
- StereolithographyStereolithographyStereolithography is an additive manufacturing technology for producing models, prototypes, patterns, and in some cases, production parts.-Technology description:...
- Von Neumann universal constructorVon Neumann universal constructorJohn von Neumann's Universal Constructor is a self-replicating machine in a cellular automata environment. It was designed in the 1940s, without the use of a computer. The fundamental details of the machine were published in von Neumann's book Theory of Self-Reproducing Automata, completed in...