What Is FDM 3D Printer? – Easy Explanation

A FDM 3d printer works by extruding a filament through a hot nozzle, it makes layer by layer on the bed to create a three-dimensional object. In a FFF or FDM 3d printer plastic filament is used as a raw material. Plastic filament is a thin wire of plastic, typically having a 2.85 mm or 1.75 mm diameter. This is the main distinction of a fdm printer from other 3d printers.

Full form of FDM in additive manufacturing or 3d printing is Fused Deposition Modeling.

FFF is fused filament fabrication and FDM is fused deposition modeling both are the same process but some brands call it as FFF and some call it as FDM. This can be useful for branding purposes.

FDM 3D Printing Process

Fused Deposition Modeling (FDM) is a common 3D printing method that creates objects layer by layer using plastic filament. Here’s a straightforward guide to the FDM 3D printing process:

1. Designing the Model:
– Begin by creating a 3D model using CAD (Computer-Aided Design) software. Alternatively, you can download pre-existing models from online repositories.

2. Slicing the Model:
– Use slicing software to convert the 3D model into a series of thin, horizontal layers. This software generates a G-code file that instructs the 3D printer on how to build the object, specifying parameters such as movement, temperature, and printing speed.

3. Printer Setup:
– Load the filament spool into the printer. Common materials for FDM printing include PLA, ABS, PETG, Flexible filament, TPU etc.
– Preheat the printer’s extruder and print bed to the appropriate temperatures for the chosen filament. Printing temperature for PLA is 210°C.

4. Printing the Object:
– The printer’s extruder heats the filament until it becomes molten.
– The extruder nozzle deposits the melted filament onto the print bed according to the path defined by the G-code.
– As the filament is extruded, it cools and solidifies almost immediately.
– After completing each layer, either the print bed moves down or nozzle moves up slightly to make room for the next layer.

5. Post-Processing:
– Once printing is complete, remove the object from the print bed.
– Additional steps, such as removing support structures, sanding, or painting, may be necessary to achieve the desired finish and functionality.

6. Quality Control:
– Inspect the printed object for defects such as layer misalignment, warping, or incomplete layers.
– Adjust printer settings for future prints to enhance quality if needed.

FDM printing is liked because it is easy to use, cheap, and can work with many different materials. However, achieving high detail or smooth surfaces might require post-processing.

Advantages and Disadvantages of FDM 3D Printing

Advantages:

1. Cost-Effective:
– FDM printers and the materials they use (filaments) are generally more affordable compared to other 3D printing methods.

2. Accessibility:
– Widely available and easy to operate, FDM printers are a favorite among hobbyists, educators, and professionals.

3. Diverse Material Options:
– Can print with a variety of materials such as PLA, ABS, PETG, TPU, flexible filament and more. Specialized filaments can offer unique properties like flexibility, strength, or heat resistance.

4. Large Print Volume:
– Many FDM printers can create larger objects due to their substantial build volumes.

5. Simple Material Changes:
– Switching filaments is straightforward, allowing users to easily change colors or materials.

6. Versatile Post-Processing:
– Various post-processing methods can be done  on it like sanding, painting, and smoothing (especially for materials like ABS).

Disadvantages:

1. Surface Finish:
– The printed objects often have visible layer lines and a rough surface, which might require additional post-processing to smooth out.

2. Printing Speed:
– Generally slower than other 3D printing technologies, especially for high-resolution prints.

3. Material Limitations:
– Limited to thermoplastic materials, so it cannot print with materials like metals or ceramics.

4. Accuracy Issues:
– Can suffer from warping and shrinkage, particularly with materials like ABS, which can affect the precision of the printed parts.

5. Mechanical Strength:
– The printed parts may be mechanically weaker compared to those produced by other methods, especially along the layer lines where the adhesion might be weaker.

6. Complexity with Supports:
– Printing overhangs and complex geometries often requires supports, which can be difficult to remove and may affect the surface quality.

Understanding these pros and cons helps in deciding if FDM 3D printing meets the requirements of your specific projects and applications.

Application of FDM 3D Printing

Here are some common uses:

• Prototyping: Designers and engineers use it to quickly and affordably create prototypes. This allows them to test and refine their designs before final production.

• Manufacturing: It produces small batches of parts for industries like automotive and aerospace. It’s useful for creating a limited number of items.

• Education: Schools and universities incorporate fdm 3d printers into their curriculum to teach design, engineering, and manufacturing. It’s a practical way for students to learn and experiment.

• Medical Field: Medical professionals and researchers use FDM 3D printing to make custom medical devices, such as prosthetics and dental implants. It can also create models of organs for surgical practice.

• Art and Design: Artists and designers utilize it to craft unique sculptures, jewelry, and other decorative items, enabling intricate and detailed designs that are challenging to produce manually.

• Personal Projects: Hobbyists uses it to make custom items, toys, and household objects, bringing their personal projects to life.

In short, FDM 3D printing is versatile and finds applications in creating prototypes, custom parts, educational tools, medical devices, and artistic creations.

FDM 3D Printing Materials

FDM, or Fused Deposition Modeling uses a plastic wire called as filament that is melted and layered to make objects. Here are some popular filaments used in FDM 3D printing:

1. PLA (Polylactic Acid)

• Easy to Use: PLA is great for beginners because it prints easily.
• Eco-Friendly: Made from renewable resources like corn starch.
• Applications: Used for prototypes, models, and everyday items.

2. ABS (Acrylonitrile Butadiene Styrene)

• Strong and Durable: ABS is tougher and more impact-resistant than PLA.
• Heat Resistance: Can withstand higher temperatures.
• Applications: Commonly used for functional parts, toys, and car parts.

3. PETG (Polyethylene Terephthalate Glycol)

• Flexible and Strong: PETG combines the ease of PLA with the strength of ABS.
• Chemical Resistant: Good for making parts that need to resist chemicals.
• Applications: Used for mechanical parts and containers.

4. TPU (Thermoplastic Polyurethane)

• Flexible: TPU is rubber-like and can bend without breaking.
• Durable: Good for making items that need to be flexible and tough.
• Applications: Used for phone cases, belts, and footwear.

5. Nylon

• Very Strong: Nylon is known for its toughness and flexibility.
• Abrasion Resistant: Good for parts that will experience wear and tear.
• Applications: Used for gears, hinges, and other high-stress parts.

6. HIPS (High Impact Polystyrene)

• Support Material: Often used as a support material for complex prints.
• Dissolvable: Can be dissolved in a limonene solution after printing.
• Applications: Used to support overhangs and complex structures in dual extrusion prints.

These materials each have their strengths and are chosen based on the specific needs of the project.

Parts of FDM 3D Printer

basic parts of a FDM 3d printer are frame, bed, extruder, hotend and control panel. Below is the brief description of all these parts:

#1. Machine Frame: Frame is the main structure of the machine on which all other parts are fixed or assembled.

#2. Extruder: It is the assembly of a few components like gear, idle wheel, stepper motor, extruder frame etc which pushes the filament to the hot-end.

#4. Bed: The machine bed is the base on which the product is made. It can be a heated bed. A heated bed means it has the ability to get heated so that the mterial sticks well to it.

#3. Control Panel: Control panel consists of a few components like display, button, knob etc to control the machine.

#5. Hot-End: This is the assemlby of heat block, heat sensor, thermistor and nozzle. This is the place where filament is melted and then pushed through the nozzle, so that the desired product is made.

#6. Stepper Motors: Stepper motors are conrolled via a digital code or program to create motions such as moving x, y and z axes and extruder to do 3d printing.

#7. Filament: Filament is not a part of this machine but it is much required as it is the raw material for making the final product.

I have written a dedicated article having a detailed list of 3d printer parts. Read it here: 3d printer parts list

Best FDM 3D Printers

The criteria for choosing the best machines are – stability, accuracy, flawless design, and build quality.

Recently, Babmu Lab has developed an FDM 3d printer that has revolutionized the whole 3d printing industry. The name of this model is the Bambu Lab A1 Mini 3D Printer. This machine is capable of printing multi-color (four color) 3d prints. Key features are as follows:

1. Multicolor Printing
2. Auto Bed Levling
3. Pre-assemled
4. No calibration required
5. Plug & Play
6. Print From App

A1 mini is very affordable. These features are not available in any other FDM printer in this price range.

FDM Printer Explainer

In this short video below, the fdm 3d printing is explained through animation. Please watch this video below:

FDM 3D Printer Price in Inida

DIY 3D Printer Kit available in india starts from INR 12000 and can go upto INR 80000.

FAQ’s

Defects in FDM 3D Printing

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