Fused Deposition Modeling
Fused Deposition Modeling (FDM), also known as Fused Filament Fabrication (FFF), is an additive manufacturing technology commonly used for modeling, prototyping, and production applications. It was developed by S. Scott Crump in the late 1980s, and the first patent for FDM was filed in 1989. Crump later co-founded Stratasys, which commercialized FDM technology.
Process
The process of FDM involves the following steps:
- Material Preparation: A thermoplastic filament, usually made from materials like ABS, PLA, or other polymers, is fed into the extruder of the FDM printer.
- Melting: The filament passes through a heated nozzle where it is melted.
- Extrusion: The melted material is extruded through the nozzle onto the build platform, layer by layer, to create the desired shape.
- Layer Deposition: The nozzle moves in three dimensions, controlled by the printer's software, to deposit the material according to the digital model. Each layer adheres to the one below it, solidifying as it cools.
- Support Structures: For parts with overhangs or complex geometries, support structures might be printed alongside the part, which can later be removed.
- Cooling and Solidification: The extruded material cools down and solidifies almost immediately after being deposited, forming the part.
Advantages
- Material Versatility: FDM supports a wide range of thermoplastic materials, allowing for diverse applications.
- Cost-Effective: Compared to other 3D printing technologies, FDM machines are generally less expensive to purchase and operate.
- User-Friendly: FDM printers are often considered more accessible for beginners due to their simplicity and lower cost.
- Post-Processing: Parts can be easily sanded, painted, or further processed after printing.
Disadvantages
- Resolution Limitations: The layer lines are visible, and the resolution isn't as fine as with some other technologies like Stereolithography (SLA).
- Mechanical Properties: FDM parts might not have the same strength as parts made from traditional manufacturing due to the layer-by-layer build method.
- Support Material: The need for support structures can complicate the printing process and require post-print removal.
Applications
- Prototyping: Rapid prototyping for testing form, fit, and function.
- End-Use Parts: Production of functional components in small quantities or for custom items.
- Educational: Used in schools and universities for teaching design, engineering, and manufacturing principles.
- Art and Design: Creating sculptures, models, and artistic pieces.
History
The technology was developed by S. Scott Crump in 1988, and the patent was granted in 1992. Stratasys was founded in 1989 to commercialize this technology. Over the years, FDM has evolved from a prototyping tool to a method capable of producing end-use parts, especially with the introduction of materials like Nylon and Polycarbonate. The patent for FDM expired in 2009, leading to a boom in the availability of low-cost FDM printers from various manufacturers.
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