FDM 3D Printing Process

Additive manufacturing/3D printing is one of the fundamental technologies driving Industry 4.0. Enterprises leverage various 3D printing technologies to transit from Industry 3.0 to Industry 4.0. But some of these 3D printing technologies are used widely by both individuals and enterprises.

Fused Deposition Modeling (FDM) is one of the 3D printing technologies that are popular with companies, startups, engineers, students, and hobbyists. In addition to being easy-to-use and budget-friendly, FDM 3D printing technology allows you to choose many materials and reuse the filaments.

You can use an FDM 3D printer to convert computer-aided design (CAD) files into solid three-dimensional parts. The machine will create the part by depositing thermoplastic filament onto a print bed layer by layer. But you must remember that FDM 3D printing is a multistep process.

You can customize and streamline the 3D printing process only by choosing the right printer, model material, and support material. Also, you need to convert the CAD file into an STL file. After completing the preliminary tasks, you have to monitor the FDM 3D printing process and perform post-processing activities to produce a part that meets your precise project needs and preset quality standards.

How to Plan and Improve the FDM SLS 3D Printing Process?

Select the Right FDM 3D Printer

Based on your predefined project needs, you have the option to choose from several types of FDM 3D printers. The FDM 3D printing machines differ from each other primarily in two aspects –mechanical nature and operational coordinate system. Hence, you need to compare the FDM 3D printers manufactured by different companies.

Combine the Right Modeling and Support Material

While planning the FDM 3D printing process, you must focus on choosing the right modeling and support materials. The modeling material will form a solid three-dimensional object, while the support material will provide support to the part as it is 3D printed.

You have the option to choose from a variety of modeling materials – ABS, PLA, PET, Nylon, PC, and TPU (flexible). Some of these materials are pure polymer, while others are composites.

Hence, they differ from each other in many aspects – printability, layer adhesion, heat resistance, impact resistance, and stress resistance. In addition to choosing the right modeling material, you must complement it with the appropriate support material.

Convert the CAD File into STL File

FDM 3D printer will produce the part based on a digital 3D model. But you have to convey information to the printer in the form of an STL file. You have to convert the CAD file into an STL file to provide information to the printer in the standard data transmission format.

Set Print or Process Parameters

FDM 3D printers allow you to set various print parameters or process parameters – layer height, build speed, nozzle temperature, build platform temperature, and cooling fan speed. You must decide the build volume and layer height according to the size of the part to be 3D-printed.

The desktop 3D printers support smaller build volumes than industrial 3D printers. If you are using a desktop 3D printer, you have to divide the large parts into smaller parts according to the build volume supported by the machine.

You can create the large part by assembling the small parts after the 3D printing process. However, you can customize the FDM 3D printing process according to precise project needs by setting or adjusting these parameters.

Start the FDM Printing Process

You have to start the FDM 3D printing process by loading the thermoplastic material into the 3D printer. The FDM 3D printer will feed the filament as threads and extrude the melted filament through extrusion nozzles.

Most FDM 3D printers feature extrusion nozzles that deposit the melted filament in both horizontal and vertical ways. The FDM 3D printer will function according to the parameters set by you. Also, it will refer to the STL file to deposit the filament in the right physical dimensions.

The melted filament will cool and solidify gradually after being deposited onto the build platform. But you can reduce the cooling time using fans attached to the extrusion head.

Remove or Separate the Support Material

Once the FDM 3D printing process is over, you have to focus on improving the surface finish by removing or separating the support accurately. You have the option to choose from two distinct support removal methods – standard and dissolvable.

You can remove the support material quickly and effortlessly by opting for the standard method. The method requires you to remove support material by cleaning the surface. However, you have to use needle-nose pliers and dental picks to remove the support material from holes, hollows, and other hard-to-reach places.

You can opt for the dissolvable method when the support material is soluble. This method requires you to remove the support material using the appropriate solvent. You need to keep the 3D-printed part in a bath till the support material is dissolved and separated. However, you must remember that each of these support removal techniques has its pros and cons.

Perform Post-Processing Activities

After removing the support material, you need to improve the 3D-printed part’s look, feel, and finish by performing a variety of post-processing activities – polishing, sanding, priming and painting, gap filling, cold welding, dipping, metal plating, and epoxy coating.

But you must remember that the post-processing activities vary according to the nature and requirements of the 3D-printed part. Hence, you have to combine the post-processing activities according to the 3D-printed part. At the same time, you must perform every post-processing activity accurately and efficiently using the appropriate toolkit.

Conclusion

FDM 3D printing technologies create opportunities for you to produce a variety of parts without putting in extra time and effort. You must focus on customizing the FDM 3D printing process according to the precise needs of each project. At the same time, it is important to improve the dimensional accuracy and print quality by implementing a slew of FDM 3D printing best practices.

However, you can save both time and resources by availing of professional FDM 3D printing services. The leading 3D printing companies use advanced 3D printers and allow you to choose from a variety of filaments. Also, you can customize the FDM 3D printing process by sharing important information related to the part or product required for your upcoming project.

About Aurum3D

We are amongst the major 3D printing service providers in Bangalore, India. We have been providing custom SLA, SLS and FDM 3D printing services to many major industries. Please feel free to get in touch with us for your custom needs, our 3D printing solutions experts will get back to you within one business day.

References

https://all3dp.com/2/cartesian-3d-printer-delta-scara-belt-corexy-polar/

https://www.hubs.com/knowledge-base/fdm-3d-printing-materials-compared/

https://smc-fluidcontrol.com/cooling-systems-in-3d-printing/

https://www.hubs.com/knowledge-base/post-processing-fdm-printed-parts/#support

How to Select the Best FDM 3D Printing Company?

While planning manufacturing projects, you have the option to choose from many additive 3D printing technologies. Some of these 3D printing technologies are more complex than others. Likewise, some 3D printing technologies are more expensive than others.

Fused Deposition Modeling (FDM) is one of the simple, fast, and cost-efficient 3D printing technologies.You can leverage this mature and popular technology to produce parts of varying types and sizes. Also, you have the option to choose from a wide range of materials and filaments for FDM 3D printers.

Many companies and startups help you leverage this industrial-grade 3D printing technology in a variety of ways.Some of these enterprises supply FDM 3D printing machines, filaments, and spare parts. At the same time, some of these companies provide FDM 3D printing services.

Hence, you can shortlist many FDM 3D printing companies and startups according to your predefined project needs. However, you can partner with the best FDM 3D printing company only by looking for these important things in the shortlisted companies.

9 Things to Look for in the Best FDM 3D Printing Company

1. Part or Prototype

You improve the quality of the part only by choosing the right 3D printing machine and filaments. You can choose the right FDM 3D printer using important parameters like build volume, layer length, and dimensional accuracy.

Likewise, you need to choose the FDM 3D printing materials with specific mechanical properties. Before comparing and shortlisting FDM 3D printing companies, you must define the requirements of the 3D printing projects clearly.

2. FDM 3D Printing Machine

The leading 3D printing companies set up facilities with multiple FDM 3D printers. Also, many 3D printing companies supply different types of FDM 3D printers. Most FDM 3D printers available in the market use Cartesian technology. These 3D printers support smaller build volumes.

But you also have the option to choose FDM 3D printers with robotic hands that can produce large structures like residential and commercial buildings. That is why; you need to invest in an FDM 3D printer that meets the needs of your current and future projects.

3. FDM 3D Printing Materials

The materials for FDM 3D printers can be broadly divided into three categories – consumer, prosumer, and industrial. Industrial filaments are used widely by enterprises due to their superior quality. At the same time, consumer filaments are easier to use than prosumer materials.

The leading FDM 3D printing service providers allow you to choose from a variety of thermoplastic filaments according to your project needs. But you need to purchase the appropriate filaments when you opt for in-house 3D printing.

4. Designing Assistance

FDM 3D printers create parts based on digital 3D models. You can create digital 3D models using CAD software. But 3D printers require you to describe the part’s surface geometry in Standard Tessellation Language (STL) language.

You can create a CAD file and convert it into an STL file using several software applications. But you should check if the best FDM 3D printing company provides 3D designing and modeling services if you are not familiar with the software.

5. Industry Expertise

Most companies and startups provide online FDM 3D printing services. But some of the companies have built a reputation by providing FDM 3D printing services to companies in the aerospace, automotive, engineering, and medical industries.

If you are planning to 3D-print a niche product it becomes essential to consider the provider’s industry expertise and resources. In addition to evaluating the niche products 3D-printed by the company, you should ascertain its industry reputation by reading customer testimonials and reviews.

6. Lead Time

You can buy FDM 3D printing machines and filaments as well as get FDM 3D printing services over the internet. But the amount of time required for receiving the machines or 3D-printed part varies across 3D printing companies.

While comparing the best FDM 3D printing companies, you must focus extensively on the lead time. It is always important to finalize a company that helps you meet project deadlines by shortening the lead time.

7. Printing Costs

You have to incur both upfront and ongoing expenses when you decide to 3D-print the part on your own. In addition to purchasing an FDM 3D printing machine and filaments, you have to spend money on post-processing activities.

But you can curtail project costs drastically by opting for professional FDM 3D printing services. That is why; the project budget will have a direct impact on the selection of the best FDM 3D printing company. You have to partner with a company without breaking the preset project budget.

8. Customer Support

Customer support is an essential aspect of the FDM 3D printing services. While availing of FDM 3D printing services, you can customize the service by interacting with the provider’s customer service team. Likewise, you need after-sales services to use the FDM 3D printing service in the longer run.

That is why; you must compare the customer support provided by the shortlisted FDM 3D printing company. In addition to checking the nature of after-sales service, you should check if you can contact the company’s customer service executives through multiple communication channels.

9. Business Relationship

You can avail of FDM 3D printing services on demand for a single project or multiple projects. But you need to form a long-term partnership with the best FDM 3D printing company if you are switching from subtractive manufacturing to additive manufacturing.

You must check the reputation and reliability of the company to ensure that your partner will meet your organization’s evolving 3D printing needs over a period of time.

Conclusion

While planning an additive manufacturing project, you have the option to choose from many FDM 3D printing companies and startups. But you can improve the resolution, dimensional accuracy, and surface finish of a part or prototype only by partnering with the best FDM 3D printing company.

Hence, you should shortlist the FDM 3D printing companies and startups according to your precise project requirements. At the same time, it is important to consider these things or parameters to compare the shortlisted companies and select the best company for your project.

References

https://www.sculpteo.com/blog/2015/07/22/3d-printing-marketplace/

https://manufactur3dmag.com/how-to-choose-the-right-3d-printing-service/

https://www.weerg.com/en/global/blog/the-ultimate-guide-to-choosing-the-best-material-for-fdm-3d-printing

https://www.raise3d.com/academy/how-to-choose-a-3d-printer-2022-3d-printer-buying-guide/