Additive Manufacturing with Fused Deposition Modeling (FDM) – The Future of Plastic Processing
In recent years, additive manufacturing has become a key technology in industrial production. Unlike subtractive manufacturing, where material is removed, additive manufacturing builds components layer by layer. One of the most popular methods is Fused Deposition Modeling (FDM), also known as Fused Filament Fabrication (FFF). This technology enables cost-effective production of prototypes, functional parts, and even serial components made from thermoplastics.
Companies are increasingly adopting industrial 3D printing solutions to shorten development times, reduce production costs, and realize custom geometries. Whether in architecture, mechanical engineering, or medical technology – FDM has become indispensable in modern manufacturing.
What is Fused Deposition Modeling (FDM)?
Basics of the FDM Process: Fused Deposition Modeling is a melting-layer process in which a thermoplastic filament is extruded through a heated nozzle and deposited layer by layer on a build platform. This way, a three-dimensional object is created, layer by layer.
Key characteristics of the FDM process:
- Cost-effective printing technology with a low entry barrier
- Ideal for prototyping, functional testing, and small series production
- Compatible with various plastics such as PLA, ABS, PETG, or ULTEM
Advantages of Additive Manufacturing with FDM
Why FDM is an attractive solution for industry and development?
- Cost efficiency: Low material costs and affordable printers make FDM attractive for startups and SMEs.
- Design flexibility: Complex geometries and custom parts can be produced without molds or tools.
- Fast availability: With rapid prototyping, designs are ready for testing in the shortest time.
- Minimal material waste: Only the required material is used – sustainable and efficient.
- Scalability: From single parts to small series – also available via online services.
Materials in FDM Printing – Plastic Diversity for Every Application
Common Filaments in Industrial FDM Printing:
The choice of the right printing material is crucial for the quality, functionality, and durability of a component. Various filaments are used in industrial environments, each offering specific properties and advantages:
- PLA (Polylactic Acid):
A biodegradable plastic that’s very easy to process. Due to low warping during printing, PLA is ideal for architectural models, demonstration pieces, and prototypes. Though less temperature-resistant, it stands out for its sustainability and ease of use. - ABS (Acrylonitrile Butadiene Styrene):
Much more robust than PLA, ABS offers high impact resistance and good heat resistance. It's commonly used for housings, technical parts, and mechanically stressed components. Post-processing (e.g., sanding or chemical smoothing with acetone) is easily possible. - PETG (Polyethylene Terephthalate Glycol):
Combines the benefits of PLA and ABS. It is tough, easy to process, chemical-resistant, and has good transparency. Ideal for functional prototypes, transparent casings, or containers in the food industry. - TPU (Thermoplastic Polyurethane):
A flexible, rubber-like material used in applications requiring high elasticity or shock absorption. Examples include seals, protective covers, vibration dampers, and ergonomic parts. - ULTEM (Polyetherimide, PEI):
A high-performance plastic that is extremely resistant to temperature, chemicals, and flames. Mainly used in aerospace, medical technology, and safety-critical applications. Requires industrial 3D printers with heated chambers and precise temperature control. - Nylon (PA):
A tough, abrasion-resistant material suitable for functional parts under high mechanical loads. It features high impact strength and flexibility – ideal for technical components.
Application Areas of FDM Technology
Where FDM is Already Used Today?
Fused Deposition Modeling is used across industries – from product development to small series production. The main application areas include:
- Industry & Mechanical Engineering:
Enables fast and cost-effective production of functional prototypes, fixtures, brackets, and production aids. Parts can be printed directly from CAD data and tested for fit and function – a key advantage in rapid prototyping. - Automotive Industry:
Design studies, assembly aids, or small components are often manufactured using FDM. ABS and ULTEM offer the necessary strength and heat resistance for real-world use. - 3D Printing in Architecture:
Architecture firms use FDM printers to produce scale models, facade elements, or form studies. PLA is especially suitable due to its detail fidelity and ease of processing. - Medical & Dental Technology:
The production of custom components such as surgical tools, drill guides, or dental models is efficient and precise with FDM. Biocompatible filaments are used here. - Aerospace:
High-performance materials like ULTEM or nylon are used in cabin equipment, functional brackets, and structural components – thanks to their properties at low weight. - Education & Research:
In universities, schools, and laboratories, FDM helps quickly build prototypes, experimental models, and research projects. The technology supports practical learning and agile development. - Packaging & Consumer Goods:
FDM is a fast way to visualize and test packaging solutions, product packaging, or design housings for new ideas.
Industrial FDM printers – such as those from Stratasys – offer advanced features for continuous use in production environments:
- Large build volume for oversized objects
- Heated build chambers for better layer adhesion
- Automated material changeover
- Compatibility with high-performance polymers
- Network integration and remote control
Conclusion: FDM as the Heart of Additive Manufacturing
Fused Deposition Modeling has established itself as a robust and versatile method within additive manufacturing. With its easy handling, cost-effective materials, and wide range of printers, FDM is suitable for both beginners and industrial users. Whether for prototypes, series parts, or architectural models – FDM technology offers a reliable and flexible solution.
