FDM Process introduction (A part of Additive Manufacturing Technique OR Commonly Known as 3D Printing). 3D printing is an evolved manufacturing technique; it is comparatively better than conventional substractive manufacturing. There is minimum wastage of material because material is added only at those locations where it is required. To make 3D model you need a 3D printer and feeding material and obviously power source. Any thermoplastic material whose melting temperature lies in the range of 150-240 deg. C can be used in FDM based 3D printing.

1. Fused deposition modeling
Under the guidance of :- Shri. SREEKANTH N V
By :- VIVEK ANAND (1BM12ME146)
Department of Mechanical Engineering
(Accredited by NBA, under Tier1, 2014-2019)
B.M.S COLLEGE OF ENGINEERING
(Autonomous Institution Affiliated to Visvesvaraya Technological University, Belgaum)
Bull Temple Road, Basavanagudi, Bangalore-560019

2. Rapid prototyping/Additive manufacturing
• Layered manufacturing
• Part is produced by producing multiple “slices”
• From 3D model [STL file] to physical object
Additive manufacturing
Fused deposition modeling
Selective laser sintering
Stereo lithography

3. Fused deposition modeling
Image source :- 3devo.eu
Fused deposition modeling (FDM):-
FDM works on an "additive"
principle by laying down material in
layers; a plastic filament or metal
wire is unwound from a coil and
supplies material to produce a part

4. Selective laser sintering
It is a technique in which a laser is
used as the power source to sinter
powdered material (typically metal)
in space defined by a 3D model,
binding the material together to
create a solid structure.
Image source :- custompartnet.com

5. Stereo lithography
In this method UV light is used for
successively printing thin layers of
an ultraviolet curable material one
on top of the other to make solid
models.
Image source :- custompartnet.com

6. Printing process
Model designing
Slicing and generating G-code
Printing
Post processing

7. Model designing
• A model can be made in any of the designing software like Solid works,
Catia, Pro-e, Sketch up, AutoCAD, 3DS max… etc.
• The designed model needs to be saved with .STL extension

8. Build parameters
• Infill percentage
• Number of Shells
• Layer Height
• Infill style
• Skin thickness

9. Build parameters
• Printing Speed (Speed while extruding)
• Movement Speed (Speed while Traveling)
• Support material

10. Slicing Software
These softwares are cross-platform program that takes 3D files (STL) and
generates path information (G-code) for a 3D Printer.
• Maker ware
• Slic3r
• KISslicer

11. KISslicer

12. Slic3r

13. Makerware

14. Printing of Ganesha model

15. Printing with multiple extruder

16. Printing with support material
Image source :- 3Ders.org

17. Readily available FDM Printers

18. ProtoCentre 999
Technology Fused deposition modeling
Build volume 230*230*230 mm cube
Printing material ABS, PLA (all thermoplastics)
Filament diameter 1.75 mm
No. of extruder Two
Nozzle bore 0.4 mm
Layer resolution 100 microns
Maximum extrusion
temperature 300 degree C
Built platform Heated type
Support material Available, Auto generated
Dual colour printing Available

19. Ultimaker2 and Duplicator4
Technology Fused deposition modeling
Build volume 285*153*155 mm cube(m)
225*145*150 mm cube(w)
Layer resolutions 100 microns
Filament diameter 1.75 mm
Nozzle diameter 0.4 mm
No. of extruder One(m)
Two(w)
Printing material PLA
Connectivity USB/ SD card

20. Pramaan mini and Prusa i3
Build volume 180*180*180 mm cube(pra)
200*200*180 mm cube(pru)
filament diameter 1.75mm
No. of extruder One
Nozzle bore 0.35 mm
Layer resolution 100 microns
Support material Uses main material
Build platform type Non heated type
Dual colour printing No
Connectivity USB/SD card

21. Fortus 250mc
Build volume 254*254*305 mm cube
Printing material ABSplus-P430
Available colours Ivory, Red, Fluorescent Yellow, White,
Blue, Custom Colors, Black,
Olive Green, Dark Grey, Nectarine
Layer thickness 0.178-0.330 mm
Support structure Soluble
Accuracy Up to 0.241 mm
No of extruder Two

22. Materials used for FDM printing
Acrylonitrile butadiene styrene
• Most widely used material in FDM. It has superior hardness, gloss toughness
and electrical insulation properties. They are stable and highly resistant to
wrapping, moisture absorption and shrinkages.
Poly lactic acid
• It is a biodegradable thermoplastic, this makes of PLA the most
environmentally friendly solution in the domain of 3D printing.PLA is
tough, but a little brittle, once it has cooled down

23. Defects in FDM Printing
• Warping and Base layer
not sticking to the bed
When some of the portion of
base layer does not stick to
the bed properly and gets
twisted and curled, it is called
warping.
Image source :- 3devo.eu

24. Defects in FDM Printing
Cause of warping and base layer not sticking to the bed
• Improper bed platform levelling
• Non heated bed
• Slow print speed

25. Defects in FDM Printing
Remedies to prevent it
• Printing with Raft on
• Proper bed preparation
• Using sticking agent
• Using heated bed
• Replacing Kapton tape after certain duration

26. Applications
• Aerospace engineering
• Digital Dentistry
• Eye care
• Prosthetic hand
• Automobile industry
• Household goods and crafts

27. Applications
Aerospace/defense/automobile industry
• For concept modeling
• Airbus is using Stratasys based FDM
machines to print aircraft parts
• NASA is using FDM parts for their next
Rover
Image source :- stratasys.com

28. Applications
Digital Dentistry
• By combining oral scanning,
CAD/CAM design and 3D
printing
Eye Care
• Prosthetic eye balls
• Instrument for eye care
Image source :- Srujana innovations

29. Applications
Prosthetic hand
By combining 3D
scanning,
CAD/CAM
design and 3D
printing
Image source :- Srujana innovations

30. Applications
Bionic arm printed in BMSCE propel lab 2

31. Challenges
• Quality of print
• Affordability
• To replace different functional parts in industries with 3D printed parts
• Reduction of defects during printing
• Repeatability