UNIT-III: Solid Based 3D Printing Systems

Introduction, Principle, Processes and Applications of Fused Deposition Modeling (FDM)

Solid-based 3D printing systems utilize solid raw materials, such as plastic filaments,
metal wires, or sheets, to construct 3D objects. These materials are melted, fused, or cut
to form the desired shape. Solid-based 3D printing is commonly used in industrial
manufacturing, prototyping, and functional part production due to its strength,
durability, and cost-effectiveness.

Introduction to Fused Deposition Modeling (FDM)

Fused Deposition Modeling (FDM) is one of the most widely used 3D printing
technologies. It is an additive manufacturing process that creates objects layer by layer
using thermoplastic materials. FDM was invented by Scott Crump in 1989 and is now
commonly used for prototyping, functional parts, and low-volume production.

Key Features of FDM:

●​ It works by heating a thermoplastic filament to its melting point and extruding it

layer by layer to build a 3D object.
●​ Affordable and widely available for hobbyists, engineers, and industries.
●​ Works with a variety of materials such as PLA, ABS, PETG, Nylon, and TPU.
●​ Offers good mechanical strength but has limitations in precision and surface finish.

Due to its simplicity, affordability, and ease of use, FDM is the most popular desktop 3D
printing technology.

Principle of Fused Deposition Modeling (FDM)

FDM operates based on surface chemistry, thermal energy, and layer manufacturing
technology. The process involves:

●​ Material Extrusion: Thermoplastic filament (spool form) is melted in a specially

designed print head.
●​ Layer-by-Layer Deposition: The molten material is extruded onto the model, where
it cools and solidifies to form the desired shape.
●​ Gradual Model Construction: The object is built layer by layer, similar to other 3D
printing systems.

Key Performance Factors

The efficiency and quality of FDM printing depend on:

●​ Material properties (column strength, flexural modulus, viscosity).

●​ Printing precision (positioning accuracy, road widths, deposition speed).
●​ Extrusion settings (volumetric flow rate, tip diameter).
●​ Environmental factors (temperature, part geometry).
Fused Deposition Modeling (FDM) Process

A typical FDM printer consists of:

●​ Two extruding nozzles (Model and Support extruders)

●​ A build platform on a linear slide
●​ Supports for filament spools

The Model Extruder prints the material for the 3D shape, while the Support Extruder
prints the support structures (if applicable). Hobbyist printers usually have a single
extruder, using the same material for both.

Depending on the printer design:

●​ The extruder head gantry moves in X & Y, while the build platform moves in Z-axis.
●​ Some versions move the print head in X and Z, while the build platform moves in Y.

FDM Process Steps

1. Part Preparation

●​ The process begins with build preparation software.

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●​ Steps include:​

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Importing the 3D design file​

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Setting layer height, orientation, and infill percentage​

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Slicing the part into layers​
Generating extruder paths & building instructions
 ●​ This step converts the 3D model into layer-based instructions for the printer.

2. FDM Machine Setup

●​ The printer is loaded with a thermoplastic filament spool for both model and
support extruders.
●​ The build platform is heated to control the cooling rate of the extruded material.
●​ The extruders are heated until the nozzle reaches the required melting
temperature.
●​ The filament is then melted and pushed through the nozzle in a thin ribbon
(roughly the size of a human hair).

3. FDM Printing

●​ The extrusion head and build platform operate in a three-axis system (X, Y, Z).
●​ The extruder deposits material layer by layer in predefined areas.
●​ Cooling fans may assist in cooling & solidifying the extruded material.
●​ Multiple passes are required to complete a layer.
●​ Once a layer is complete, the build platform or print head moves in the Z-axis for
the next layer.
●​ This process repeats until the entire object is built.

4. FDM Part Removal

●​ The completed part is carefully removed from the build platform.

●​ Any support structures are detached.

5. Post-Processing

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●​ The printed part undergoes finishing processes, such as:​

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Removing residual support material​

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Smoothing or refining surface details​
Applying coatings or treatments based on application requirements

Applications of FDM 3D Printing

FDM is used across various industries due to its cost-effectiveness, material variety, and
ease of use.

1. Conceptualization & Presentation Models

●​ FDM models can be marked, sanded, painted, and drilled for an enhanced finish.
●​ Used in product visualization and presentations to closely resemble actual
products.

2. Prototyping for Design & Functional Testing

●​ FDM allows functional prototypes with ABS parts having 85% of the strength of
actual molded components.
●​ Useful for design validation, analysis, and consumer product testing.
3. Patterns & Masters for Tooling

●​ FDM models can serve as patterns for investment casting, sand casting, and
molding.

4. Industrial & Manufacturing Applications

●​ Low-volume production of complex parts.

●​ Rapid manufacturing for quick turnaround times.
●​ Engineering models for dimensional and functional validation.
●​ Functional testing of product designs.
●​ Jigs, fixtures, and tooling for manufacturing and assembly processes.

5. Aerospace & Automotive Applications

●​ FDM is used for parts with approved material for aeronautics.

●​ Possibility of chromating ABS parts for enhanced durability.

6. Small-Scale & Cost-Effective Manufacturing

●​ Short-series (low-volume) production for industries requiring limited quantities.

●​ Lower-cost part fabrication, reducing expenses compared to traditional
manufacturing methods.

Advantages of FDM 3D Printing

1. Fabrication of Functional Parts

●​ FDM can fabricate prototypes using materials similar to actual molded products.
●​ Using ABS material, FDM can create fully functional parts with up to 85%
strength of an injection-molded part.
●​ Ideal for rapid prototyping and functional testing.

2. Minimal Wastage

●​ The process builds parts by extruding semi-liquid material, ensuring only the
required material is used.
●​ Material wastage is minimal, as there is little need for post-cleaning after
printing.

3. Easy Support Removal

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●​ Support structures can be easily removed using:​

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Break Away Support System (BASS) – Supports can be manually broken off.​
WaterWorks Soluble Support System – Supports dissolve in water.
●​ Reduces post-processing time and makes handling prototypes more convenient.

4. Ease of Material Change

●​ Build materials come in spool or cartridge form (e.g., Dimension or Prodigy Plus).
 ●​ Simple handling and quick material change ensure easy machine operation and
low maintenance.

5. Wide Variety of Materials

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●​ FDM technology supports multiple thermoplastic materials, including:​

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ABS, ABS/PC, PC, PLA, PET, PA​

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Fiber-reinforced materials​
High-performance engineering plastics

6. Other Key Benefits

✔ No post-curing required​
✔ Easy removal of support structures​
✔ Capability to manufacture large parts without deformation​
✔ Possibility of combining multiple materials in a single print

Limitations of FDM 3D Printing

1. Restricted Accuracy

●​ Limited precision due to the filament shape and size.

●​ Filaments typically have a diameter of 1.27 mm, setting a constraint on detail
resolution.
●​ Results in layer lines and a less smooth surface finish compared to other 3D
printing technologies.

2. Slow Printing Process

●​ Build speed is limited because the entire cross-sectional area must be filled layer
by layer.
●​ Restricted by extrusion rate and material flow rate from the nozzle.
●​ Plastic viscosity is high, preventing significant speed improvements.
●​ Longer print times for large or complex parts.

3. Unpredictable Shrinkage and Distortion

●​ Rapid cooling causes internal stresses, leading to shrinkage and warping.

●​ Difficult to predict and control these deformations.
●​ Experienced users can compensate by adjusting process parameters, but this
requires trial and error.