FDM 3D printing is a popular method for making three-dimensional objects. FDM stands for Fused Deposition Modelling. It is also known as Fused Filament Fabrication or FFF. This guide will explore the capabilities of FDM 3D printers. It will discuss how they are used from making prototypes to producing final parts. This article will also highlight how the Intamsys FUNMAT Series is used for FDM printing.
What is FDM 3D Printing?
FDM 3D printing is a type of additive manufacturing. This means that parts are built layer by layer. FDM 3D printers use thermoplastic filaments. The printer heats the filament and then extrudes it through a nozzle. The melted material is deposited on a build platform. Once the material cools, it becomes solid. This process continues until the part is complete.
How Does FDM 3D Printing Work?
- Filament Loading: A spool of thermoplastic filament is loaded into the printer.
- Nozzle Heating: The printer heats the nozzle to the required temperature.
- Material Extrusion: The printer feeds the filament through the heated nozzle. The melted material is extruded.
- Layer Deposition: The extrusion head moves along the X, Y, and Z axes, depositing the material layer by layer.
- Cooling and Solidification: The deposited material cools and solidifies.
- Part Completion: This process repeats until the 3D printed part is finished.
Advantages of FDM 3D Printing
FDM 3D printing offers many benefits:
• Material Diversity: FDM printers can use a wide range of materials. These include PLA, ABS, PETG, PC, and high-performance materials.
• Cost-Effective: FDM is generally a more affordable 3D printing method.
• Easy Iteration: It is easy to modify designs and print new parts quickly.
• Simple Cleanup: FDM printing requires minimal cleanup.
• Versatility: FDM printers can be used for many applications from prototypes to end-use parts.
• Speed: FDM printers can create parts quickly.
FDM 3D Printing for Prototyping
FDM 3D printing is widely used for prototyping. It allows designers and engineers to quickly create models for testing. The ability to make quick design changes is very helpful. FDM allows for fast and cost-effective design verification.
FDM 3D Printing for Production
FDM 3D printing is also used for production. It is suitable for small-batch manufacturing. FDM can produce end-use parts with good mechanical properties. The use of high-performance materials expands its production capabilities.
Materials for FDM 3D Printing
FDM 3D printers can use a wide variety of materials:
• PLA: A common, easy-to-print material.
• ABS: Known for its strength and durability.
• PETG: A strong and flexible material.
• PC (Polycarbonate): A very strong material with high-heat resistance.
• Nylon: A strong and flexible material often used with carbon fiber.
• PEEK: A high-performance material known for its strength and heat resistance.
• PEKK: A high-performance material with mechanical properties similar to PEEK.
• PEI (ULTEM): An extremely strong, high-temperature material.
• Carbon Fiber-Filled Filaments: Materials mixed with carbon fiber to increase strength and stiffness.
Considerations for FDM 3D Printing
• Layer Height: The thickness of each layer can affect print quality. Smaller layer heights mean higher quality.
• Build Size: The size of the object that can be printed is limited by the printer’s build volume.
• Nozzle Temperature: The temperature of the nozzle must be set correctly to ensure proper extrusion.
• Bed Temperature: A heated bed helps to prevent warping.
• Support Materials: Complex parts may need support structures, especially when using dual extrusion for soluble supports.
Desktop vs Industrial FDM 3D Printers
There are two main categories of FDM 3D printers: desktop and industrial.
| Property | Industrial FDM | Desktop FDM |
|---|---|---|
| Standard Accuracy | ± 0.3% (lower limit: ± 0.2 mm) | ± 0.5% (lower limit: ± 1.0 mm) |
| Typical Layer Height | 0.18 - 0.5 mm | 0.10 - 0.25 mm |
| Minimum Wall Thickness | 1 mm | 0.8 - 1 mm |
| Maximum Build Volume | Large (e.g. 900 x 600 x 900 mm) | Medium (e.g. 200 x 200 x 200 mm) |
| Common Materials | ABS, PC, ULTEM, PEEK | PLA, ABS, PETG |
| Support Material | Water-soluble/Break-away | Same as part (typically) |
| Production Capability | Low/Medium | Low |
| Machine Cost | $50000+ | $500 - $5000 |
The Intamsys FUNMAT Series for FDM Printing
The Intamsys FUNMAT Series is designed for both prototyping and production. These printers are known for their high-temperature capabilities and multi-material support. Here’s how they fit into the world of FDM 3D printing:
• FUNMAT HT: This printer is designed for high-performance materials like PEEK and PEKK. It has a heated chamber and a high-temperature extruder. It is known as an affordable desktop PEEK 3D printer.
• FUNMAT PRO Series: These printers are designed for industrial applications. They offer features such as dual extruders, high-temperature printing, and large build volumes.
o FUNMAT PRO 310 NEO: This is an industrial high-speed 3D printer. It is designed for high-throughput printing. It is ideal for small batch production.
o FUNMAT PRO 410: This printer is built to bring industrial performance to the next level. It is known as an industrial-grade PEEK 3D printer. It has a heated build plate and a high-temperature extruder.
o FUNMAT PRO 610HT: This is a large build volume industrial 3D printer. It has a 300°C heated chamber and can print most high-performance thermoplastics.
Key Features of the Intamsys FUNMAT Series
• High-Temperature Extruders: Can reach up to 500°C for high-performance materials.
• Heated Chambers: Maintain consistent temperatures for printing advanced materials.
• Multi-Material Capability: Can print a wide range of materials.
• Dual Extrusion: Allows for printing with support materials and multiple colors.
• IDEX: Some models have independent dual extruders for increased versatility.
• Automatic Leveling: Ensures a level print bed for high print quality.
• Filament Runout Warning: Enhance printing success and efficiency.
• INTAMSUITE NEO Software: Optimizes the printing process.
• Not locked to specific filaments: INTAMSYS' 3D printers are NOT locked to INTAM™ Filaments.
Benefits of Using Intamsys FUNMAT Series for FDM
• High-Performance Printing: Designed for high-temperature and high-performance materials.
• Industrial-Grade Quality: Provides reliable and accurate printing.
• Versatility: Can handle both prototypes and production parts.
• Large Build Volumes: The FUNMAT PRO 610HT has a large build volume for bigger parts.
• User-Friendly: Easy to use for both beginners and experts.
Conclusion
FDM 3D printing is a versatile technology. It is used for both prototyping and production. The method is useful in many industries. The Intamsys FUNMAT Series offers advanced features for FDM printing. The high-temperature and multi-material capabilities make them a good choice for a range of applications. Whether for prototypes or end-use parts, FDM and the FUNMAT Series offer reliability and quality.