Fused Deposition Modeling (FDM)
Fused Deposition Modeling (FDM) is an additive manufacturing technology used for creating prototypes, models, and production parts. It is one of the most widely used methods in the field of 3D printing.
History
- FDM was developed by Scott Crump in the late 1980s. Crump, along with his wife Lisa Crump, founded Stratasys in 1989, which later commercialized the technology.
- The first patent for FDM was granted to Crump in 1992, and the technology was introduced to the market under the brand name FDM in 1991.
- Stratasys held the trademark for "FDM" until it was allowed to lapse in 2009, after which the term became generic in the 3D printing industry.
Process
The FDM process involves the following steps:
- Modeling: A 3D model is created using Computer-Aided Design (CAD) software or acquired through 3D scanning.
- Slicing: The model is then sliced into thin layers using slicing software, which converts the 3D model into a series of 2D layers.
- Printing:
- A 3D printer with an FDM mechanism heats a thermoplastic filament, typically made from materials like PLA, ABS, or Nylon, to its melting point.
- The filament is extruded through a nozzle, which deposits the material layer by layer onto a build platform.
- The extruder head moves in the X and Y axes to lay down the material, while the Z-axis movement controls the height for each new layer.
- Support Structures: For parts with overhangs or complex geometries, support structures are printed along with the part. These supports are later removed.
- Cooling: The printed part cools and solidifies after each layer is deposited, allowing for the next layer to be added.
- Post-Processing: This can include removing support structures, sanding, painting, or applying other surface treatments to enhance the part's appearance or functionality.
Applications
- Prototyping: FDM is extensively used for rapid prototyping due to its cost-effectiveness and speed.
- Education and Research: Schools and universities use FDM printers for teaching and research purposes.
- Manufacturing: Used for producing end-use parts in industries like automotive, aerospace, and medical.
- Art and Design: Artists and designers use FDM to create intricate sculptures, jewelry, and other artistic works.
Advantages
- Cost-effective for small production runs and prototyping.
- Wide range of materials available, allowing for different mechanical properties.
- Relatively simple technology with a broad user base, making it accessible for hobbyists and professionals alike.
Disadvantages
- Lower resolution and surface finish compared to other 3D printing technologies like Stereolithography (SLA).
- Limited material properties due to the thermal expansion and contraction during the printing process.
- Support structures can be difficult to remove and may leave marks on the finished product.
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