Fused Deposition Modelling (FDM)

FDM (also known as Fused Filament Fabrication or FFF) is an additive manufacturing process which extrudes molten plastic through a nozzle, and builds up the print in layers.

Interesting fact: FDM is the most widely used technology across most industries, and likely the first process you think of when 3D printing comes up. But it wasn't the first 3D printing process.... SLA was!

How it works

Spools of material are loaded into the machine, fed by rollers which pull it up to the build head. Once there, the build head heats the plastic and extrudes it out of the nozzle in a predetermined XY path.

To fill an area, multiple passes are required, similar to colouring in a shape with a marker. When the printer finishes a layer, typically the build platform descends and the machine begins work on the next layer. In some machine setups, the extrusion head moves up.

Support material is applied when there is an overhang on the part design, this can either be a specific support material, or the same material as the part is made from, printed in an easy to remove pattern.

This process repeats until the part is finished.

Materials Used

Typically, the UltiMaker printers run PLA, the Stratasys F270 runs ABS, the Stratasys F450 runs Nylon Carbon Fibre, and the Markforged runs Onyx and Carbon Fibre. Please speak to us if you require a non standard material.

Sample parts are on show in HPO and Sheaf workshops if you'd like to see how your parts will come out.

Red printed part with supports in white. Some supports can be dissolved, whilst others require manual removal

FDM isn't great at printing threads, but it is great for using heat set inserts or captive nuts for additional strength in assemblies

FDM is great for all kinds of mold making, e.g. carbon fibre layups, vacuum forming, and silicone molding

What can I print on it?

We have four types of FDM printers in the Digital Workshops, 6 x UltiMaker S5, 1 x Stratasys F270, 1 x Stratasys Fortus 450, and 1 x Markforged Mark 2.

FDM technology is great for rapid prototyping, create everything from quick design iterations to functional final parts with high strength materials. The UltiMakers are available for student use following a successful induction, and the other machines can be run by technicians for student prints.

One of the main design considerations is that parts can be weak in the Z orientation of printing. So if you need parts to be strong in a certain area, change the orientation of your part to allow for strength based on printing. The Markforged can also lay carbon fibre strands in predetermined areas to increase the strength of parts.

If you're unsure if the part you're designing will print, or which machine would be best for your needs, come and have a chat with one of the Digital Workshop Technicians and we can give you some advice.

Printing Workflow - How to print using the UltiMakers

Design and Slice

Remove Supports

Design your part: Use any CAD software to design your model, and export it in a 3D printable file format (STL, OBJ or 3MF).
Complete an UltiMaker Induction: Go to UltiMaker Induction, watch the induction video and complete the form on that page. Your details will then be added to Connect2. Please allow 24 hours for your details to be added.
Book an UltiMaker: Using Connect2, book an UltiMaker slot for either Sheaf or HPO.
Set up the file for printing: Open your file in Cura (available on AppsAnywhere or on one of the PCs by the printers), and orient, support and layout your STL files ready for printing. Slice the file and save the .umf file to one of the memory sticks in the printers.
Ask for a quote: Find a technician and ask them for a quote based on how much material the software says your print will use. They will provide you with an invoice which you can pay for in stores.
Prepare the printer: Ensure the printer you want to use has the correct colour of material loaded, and then select your file from USB storage and hit print.
Print: Sit back and relax as the machine does it's magic.
Support removal: Remove your part from the machine platform using the scrapers nearby, and manually remove the support material using hand tools.
Spray painting and finishing: Sand and spray paint your parts if needed.

Printing Workflow - How to print using the Stratasys F270, Fortus 450 or the Markforged Mark Two

Design and Slice

Remove Supports

Design your part: Use any CAD software to design your model, and export it in a 3D printable file format (STL, OBJ or 3MF).
Set up the file for printing: Bring your file to one of the Digital Workshops technicians along and we will set up your file on the machine software ready for printing. Note: If printing on the Markforged, technicians will work with you to determine where to place carbon fibre strands.
Prepare the printer: The technicians will then get the printer ready by loading material and performing machine checks.
Print: Sit back and relax as the machine does it's magic.
Support removal: Support can either be manually removed or technicians will put your parts into a solution to dissolve any support material.
Spray painting and finishing: Sand and spray paint your parts if needed.

How much will it cost?

The cost of printing your part(s) will depend entirely on the size of the part and which materials/printer you decide to use.

All prints are charged at a price per gram of material, and you'll be given a quote before your parts start printing, so you can decide how to proceed.

Page updated

Google Sites

Report abuse