3D printing technology FDM is leading in the production of prototypes and technical products with low cost and high efficiency. Explore the most popular industrial FDM printers and their applications across various industries.
1. What is 3D Printing Technology FDM?
1.1. The Emergence of FDM Technology
FDM (Fused Deposition Modeling) 3D printing technology was developed by S. Scott Crump in 1980 from Stratasys. The company sold the first machine using FDM technology, called "3D Modeler," in 1992. Materials used in FDM include thermoplastics such as ABS, polyamide, nylon, and wax.
The printing speed of FDM technology depends on the size and complexity of a printed object. Small objects can be printed relatively quickly, while more complex parts require more time.
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1.2. What is FDM 3D Printing?
FDM 3D printing, also known as FFF (Fused Filament Fabrication), is a 3D printing technology that uses thermoplastic polymer filament to create 3D objects by layering materials on top of each other to form a complete object. The material is heated to melt, and then extruded following a pattern either beside or onto previous extrusions, creating layer after layer of the product.
Structure of an FDM 3D Printer
Simply put, it involves taking a plastic filament and pressing it through a hot nozzle, melting it, and then depositing it layer by layer onto the print bed. You can think of FDM as a hot glue gun, but instead of glue, it uses plastic filament. The machine melts the plastic filament and extrudes it in thin layers onto a surface, with each layer building upon the previous one to form the 3D object.
2. How FDM Technology Works
2.1. Structure of the FDM Printing System
2.1.1. 3D Printer Frame:
This is the supporting structure for the entire system, including the X, Y, and Z axes. It provides stability and rigidity to the printer.
2.1.2. Print Bed:
- This is the flat surface where the 3D object is created, and the print head extrudes material onto it.
- During the printing process, the Z-axis system moves the print bed step by step in equal increments to create the layers that form the printed object.
- The print bed can be made of various materials such as glass, metal, plastic, or heated surfaces.
- Structure of the FDM 3D Printing System
Structure of FDM 3D printing system
2.1.3. Print Head:
- The print head is the most crucial component, responsible for heating and extruding the molten material through a nozzle to form the product.
- Factors like nozzle size and extrusion speed affect the precision the printer can achieve, as well as the printing speed.
Key components include:
- Nozzle: Comes in various sizes, influencing the resolution of the printed object. The extrusion width can vary between 0.193mm to 0.965mm.
- Heating Element: Melts the plastic material.
- Temperature Sensor: Helps regulate the nozzle’s temperature.
- Stepper Motor: Controls the movement of the print head along the X and Y axes.
FDM 3D printer printhead
2.1.4. 3D Printing Material Supply System:
- Provides the printing material (usually plastic filament) to the print head.
- Can be either an automatic or manual feed system.
2.1.5. Control System:
- Includes the motherboard, microcontroller, and other electronic components.
- Controls the entire printing process, from reading the 3D file to moving the print head and adjusting the temperature.
- The computer reads 3D files in STL format, the standard format for representing solid objects in the prototyping industry.
2.1.6. Software:
- Slicing Software: Converts the 3D file into 2D layers, adjusts the model's size, position, and orientation for printing, and generates GCODE, which the printer understands.
- Printer Control Software: A user interface that allows control over printing parameters such as speed, temperature, and layer thickness.
Materialise Magics slicing software interface
2.2 FDM 3D Printing Process
2.2.1. Designing the 3D Model:
CAD Software: Programs like SolidWorks, Fusion 360, and Blender are used to create detailed 3D models.
2.2.2. Slicing:
- Converting the 3D model into 2D layers: Slicing software like Materialise Magics, Cura, or PrusaSlicer divides the 3D model into hundreds or thousands of thin 2D layers.
- Customizing parameters: Users can adjust parameters such as layer thickness, printing speed, fill density, and nozzle temperature to optimize print quality.
2.2.3. Preparing the Printer:
- Loading the printing material: Plastic filaments like PLA, ABS, or PETG are loaded into the printer.
- Calibration: Ensure the print head and print bed are properly aligned.
- Cleaning the print surface: The print bed is cleaned to ensure good adhesion for the first layer.
- Adjusting important print parameters: In addition to nozzle size and extrusion speed, factors like nozzle temperature, print head movement speed, and fill density must be adjusted to affect the final product quality.
3D FDM Printing Canyon Mountain Bike Parts Using BigRep ONE 3D Printer
Read the full case study, here
2.2.4. Starting the FDM 3D Print:
- Heating the nozzle: The nozzle is heated to the appropriate temperature for the type of material being used.
- Extruding the material: The print head moves according to the slicing software’s instructions, extruding molten material layer by layer onto the print bed to form the object.
- Supports: Many 3D-printed details, such as overhangs or hollow sections, require additional support structures to maintain stability during printing. Common support types (soluble and breakaway) should be explained, along with how they are created.
2.2.5. Post-Processing:
Removing support material (if any), sanding, painting, or coating the surface of the object to improve aesthetics and durability.
3. Advantages and Disadvantages of FDM 3D Printing Technology
3.1. Advantages
- Affordable Cost: FDM 3D printers and their materials are generally more affordable compared to other 3D printing technologies.
- Ease of Use: FDM printers are relatively easy to operate and maintain, making them suitable for beginners.
- Fast Printing Speed: Compared to some other 3D printing technologies, FDM can produce objects relatively quickly and with high reliability. It is widely applied in fields ranging from rapid prototyping to the production of replacement parts.
- Variety of Materials: A wide range of thermoplastics can be used, allowing for the creation of products with different properties.
- Low Noise: FDM printers generally operate with minimal noise, making them suitable for various environments.
Vinnotek's FDM 3D printing products
3.2. Disadvantages
- Precision: The accuracy of small details can be limited due to the layer thickness.
- Durability: The strength of FDM 3D printed objects may not be as high as those produced by other methods, especially when subjected to heavy loads.
- Surface Finish: FDM-printed objects often have visible layer lines and may require post-processing to achieve a smoother surface.
- Supports: Complex parts may require support materials, and removing these supports can be time-consuming and labor-intensive.
4. Popular Industrial FDM 3D Printers
FDM 3D printing is becoming an essential tool for businesses and organizations across various sectors. Below are some popular industrial FDM 3D printers and their key features:
4.1. Mingda MD-400D
Mingda MD-400D is an excellent choice for businesses needing to print complex prototypes with high performance. It features an independent dual extrusion (IDEX) system, allowing for the simultaneous printing of two models, doubling productivity and halving wait times.
4.1.1. Key Features:
- IDEX Dual Extrusion System: Two extruders move independently, supporting printing two objects at once or creating mirrored models, increasing efficiency.
- Print Volume: 400 x 400 x 400 mm, suitable for medium to large-sized projects.
- High Printing Speed: Up to 300 mm/s, improving printing efficiency.
- Mirror and Copy Modes: Ideal for batch production or creating symmetrical models.
- Automatic Filament Detection: The printer pauses and alerts when filament runs out, preventing print interruptions.
4.1.2. Applications:
- Design and Prototyping: Creates complex and detailed models faster.
- Small Batch Production: Suitable for design studios and businesses looking to increase print productivity.
4.2. Mingda MD-1000D
Mingda MD-1000D is a large-scale industrial FDM 3D printer ideal for projects requiring large and precise parts. It is perfect for businesses needing to produce large or high-strength components.
4.2.1. Key Features:
- Large Print Volume: 1000 x 1000 x 1000 mm, allowing for large products without the need for assembly.
- Fast Printing Speed: Up to 300 mm/s, reducing production time.
- Dual Cooling System: Ensures stable and high-quality printing.
- Auto-leveling and Flexible Print Platform: Improves precision and makes it easy to remove printed objects.
4.2.2. Applications:
- Construction and Architecture: Printing large-scale models and structural components.
- Industrial Manufacturing: Producing molds, jigs, and large mechanical parts.
4.3. BigRep ONE
BigRep ONE is a large-format 3D printer with an affordable price point, widely trusted by designers and manufacturers globally. Its ability to print large objects quickly and accurately makes it ideal for bringing design concepts to life.
4.3.1. Key Features:
- Large Print Volume: 1000 x 1000 x 1000 mm, for printing large objects without seams.
- High-power Extruder: Equipped with interchangeable nozzles (0.6, 1.0, 2.0 mm) for precise and fast printing.
- Heated Print Bed: Ensures good adhesion and stable performance.
- User-friendly: Intuitive controls, easy setup, and remote progress monitoring via webcam and power outage recovery.
4.3.2. Applications:
- Product Design: Ideal for producing large models for industries like automotive and aerospace.
- Industrial Manufacturing: Printing large mechanical components and tools.
- Architecture: Creating large-scale architectural models.
4.4. Raise3D Pro3
Raise3D Pro3 is a professional-grade FDM 3D printer equipped with a dual extruder system, designed to print complex models with high precision. It is ideal for small-scale production and rapid prototyping.
4.4.1. Key Features:
- Dual Extrusion System: Allows for printing two materials or two colors simultaneously without compromising quality.
- Auto-bed Leveling: Facilitates quick setup and ensures high precision.
- Filament Detection and Power Loss Recovery: Saves print progress and resumes printing after power outages or filament changes.
- Airflow Management with HEPA Filter: Ensures a stable and clean printing environment.
4.4.2. Applications:
- Small Batch Production: Suitable for producing small, high-precision parts.
- Education and Research: Used in educational settings to test and develop new designs.
4.5. Raise3D E2
Raise3D E2 is a desktop 3D printer with an independent dual extrusion (IDEX) system, designed for easy maintenance and operation. It is compatible with various flexible materials like TPU.
4.5.1. Key Features:
- IDEX Dual Extrusion System: Allows independent printing of two models or mirrored prints.
- Auto-bed Leveling: Ensures optimal print quality.
- BuildTak FlexPlate: A flexible print surface that makes it easy to remove models without damage.
- Power Loss Recovery and Filament Detection: Ensures uninterrupted prints even during power outages.
4.5.2. Applications:
- Education: Ideal for teaching and hands-on 3D printing with various materials.
- Product Design: Allows designers to quickly prototype and test models.
- Small Mechanical Parts: Suitable for manufacturing precise mechanical components.
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5. Common Materials Used in FDM 3D Printing
FDM 3D printing technology uses a wide variety of thermoplastic filaments, offering flexibility for many different applications. Here are some of the most common materials:
5.1. PLA (Polylactic Acid)
- Eco-friendly: PLA is a biodegradable plastic made from renewable resources like corn starch, making it environmentally friendly.
- Easy to Print: It’s one of the easiest materials to print, with low warping and good layer adhesion.
- Applications: Ideal for models and prototypes that don’t require high mechanical strength, like decorative objects, educational tools, and low-stress prototypes.
5.2. ABS (Acrylonitrile Butadiene Styrene)
- Durable and Heat-resistant: ABS is known for its durability and higher resistance to heat compared to PLA.
- Mechanical Strength: It’s often used for parts that require toughness, such as enclosures, housings, and automotive parts.
- Applications: Ideal for engineering applications where strength and durability are important.
5.3. PETG (Polyethylene Terephthalate Glycol)
- Balanced Properties: PETG combines the ease of printing of PLA with the durability of ABS. It’s impact-resistant, flexible, and has some transparency.
- Chemical Resistance: PETG is resistant to chemicals, making it ideal for functional parts that need durability and resistance to wear.
- Applications: Often used for parts that need to be strong, flexible, and resistant to impact, such as mechanical parts, bottles, and packaging.
5.4. Nylon
- High Performance: Nylon offers superior mechanical strength, flexibility, and durability. It’s also resistant to wear and tear, making it perfect for industrial applications.
- Applications: Commonly used for gears, bearings, and other parts that require durability and mechanical strength.
5.5. Carbon Fiber Reinforced Filaments
- Lightweight and Strong: These filaments are infused with carbon fiber, making them lightweight yet very strong and stiff.
- Applications: Ideal for industries that need strong but lightweight parts, such as aerospace, automotive, and performance sports equipment.
6. Applications of FDM Technology
FDM 3D printing is increasingly proving its worth across a variety of industries, thanks to its flexibility, low cost, and ability to create complex products. Here are some of the most common applications:
6.1. Prototyping (Rapid Prototyping)
- Rapid Turnaround: FDM is a go-to choice for rapid prototyping, allowing businesses to shorten product development cycles. By quickly and affordably creating prototypes with a high level of detail, designers and engineers can easily test and iterate on designs before moving to mass production.
- Applications: From automotive parts to consumer products, FDM is widely used to create functional prototypes that closely resemble final products.
6.2. Industrial Manufacturing
- Production of Technical Components: FDM is used for printing mechanical parts, production tools, and replacement parts. With the ability to print with engineering-grade materials like nylon and carbon fiber, industries can produce durable machine components on-demand.
- Applications: Common in sectors like automotive and electronics for producing jigs, fixtures, and end-use parts.
6.3. Education and Research
- Hands-on Learning: FDM 3D printing has become an essential tool in education, allowing students and researchers to bring their ideas to life with 3D models. It fosters creativity and innovation, from basic designs to complex projects in fields like engineering, architecture, and medicine.
- Applications: Universities and research institutions use FDM to teach design principles, test mechanical parts, and even create medical models for study.
FDM 3D printing technology is increasingly proving its vital role in manufacturing and design with its ability to deliver rapid, accurate, and cost-effective prototyping.
If your business is looking for the right FDM 3D printing solution, contact Vinnotek today for detailed consultation and optimized solutions tailored to your production needs!
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