Fused Filament Fabrication (FFF)

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

Interesting fact: FFF 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

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

FFF 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 FFF printers in the Digital Workshops, 6 x UltiMaker S5, 1 x Stratasys F270, 1 x Stratasys Fortus 450, and 1 x Markforged Mark Two.

FFF technology is great for rapid prototyping, create everything from quick design iterations to functional final parts with high strength materials. All printers are 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 BambuLabs X1C, Ultimaker S5, 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: Email your file to acmdigitalworkshop@shu.ac.uk and one of the Digital Workshops technicans 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.

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