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What is FDM 3D Printing?

Fused Deposition Modeling (FDM) is an additive manufacturing technology that uses a heated nozzle to extrude thermoplastic filament layer by layer to create a solid object. Valued for itscost-effectiveness, material versatility and ability to produce functional prototypes and end-use parts, FDMis widely used in the automotive, aerospace, and industrial sectors, thanks to its compatibility with high-performance materials.

FDM Materials

PA12 CF

PA12 CF is a composite material based on PA12 (polyamide 12) reinforced with short carbon fibers. This material offers a unique combination of strength, lightness, and durability, making it ideal for structural parts, tooling, and functional prototypes in automotive, aerospace, and manufacturing industries.

ASA

ASA (Acrylonitrile Styrene Acrylate) is a polymer known for its excellent weather resistance, UV stability, and impact strength, making it perfect for outdoor applications. It maintains its dimensional stability and color over time, making it suitable for signage, urban furniture, and automotive or marine industry prototypes.

ABS

ABS is a widely used thermoplastic in FDM technology. It offers a balance of strength, durability, and ease of processing. It is commonly used for functional prototypes, mechanical parts, and industrial components due to its ability to withstand mechanical stress and moderate temperatures.

ABS ESD

ABS ESD is an electrostatic discharge-safe ABS thermoplastic, ideal for sensitive electronic applications. It prevents static buildup, making it suitable for enclosures, electronic assembly, and packaging in ESD-sensitive environments.

ULTEM 9085

ULTEM 9085 is an advanced thermoplastic polymer composed of polyetherimide (PEI) and polycarbonate (PC). It offers exceptional hydrolysis and acid resistance, along with high mechanical and thermal performance. It is flame-resistant and self-extinguishing, making it suitable for automotive, railway, and aerospace applications, including brackets, air ducts, electrical housings, and air filter boxes.

PA6

PA6 (polyamide 6) is a thermoplastic polymer known for its excellent strength, stiffness, and wear resistance. It provides high mechanical strength, dimensional stability, and chemical resistance, making it suitable for mechanical parts, automotive components, sports equipment, and power tools.

PA12

PA12 (Polyamide 12) is a high-performance thermoplastic known for its strength, mechanical resistance, and dimensional stability. Its wear, fatigue, and chemical resistance make it ideal for automotive, aerospace, electronics, and industrial applications.

PP

PP (polypropylene) is a lightweight thermoplastic polymer with good chemical resistance, ductility, and impact strength. It is commonly used for prototypes, functional parts, and consumer goods such as containers, casings, and automotive components.

PA6 CF

PA6 CF is a polyamide 6 composite reinforced with short carbon fibers. It offers superior mechanical strength, stiffness, and thermal stability compared to virgin polyamide, making it ideal for high-stress applications in aerospace, motorsports, and manufacturing.

PEEK

PEEK (polyetheretherketone) is a high-performance thermoplastic known for its outstanding mechanical, thermal, and chemical resistance. It is widely used in aerospace, medical, and oil & gas industries as a metal replacement for mechanical components exposed to extreme environments.

PEEK CF

Thermoplastic polyurethane (TPU) is a material that mimics rubber and is widely used in industry for its flexibility and durability. It is suitable for both prototypes and series production, combining high elongation with outstanding tear resistance. Its properties include resilience, rigidity, good chemical resistance, consistent performance over time, and high-detail resolution. TPU finds applications in various sectors, including automotive, fashion, medical devices, and sports equipment, due to its versatility and adaptability to different conditions.

PA CF (Onyx)

Onyx is a nylon-based composite material reinforced with short carbon fibers, offering a combination of strength, lightness, and durability. It is used for structural parts, tooling, and functional prototypes in the automotive, aerospace, and manufacturing industries.

PA (Onyx) Continuous CF

Onyx Continuous Fiber - Carbon combines nylon Onyx with continuous carbon fibers, resulting in exceptional strength and stiffness. It is ideal for structural applications where lightweight and high strength are required.

PA CF (Onyx) Flame retardant

Onyx FR (Flame Retardant) is a carbon fiber-reinforced composite designed for fire resistance. Processed via FDM, it combines mechanical strength with flame-retardant properties, ideal for aerospace, automotive, and electronics applications.

PA CF (OnyX) ESD

PA CF (Onyx) ESD is a carbon fiber-filled nylon composite with ESD-safe properties, offering mechanical strength and surface finish similar to Onyx. Its surface resistivity prevents electrostatic charge buildup, making it ideal for high-durability and advanced mechanical applications.

ULTEM 1010

ULTEM 1010 is a high-performance polyetherimide (PEI) thermoplastic with excellent tensile strength, chemical resistance, and high thermal stability, making it suitable for sterilizable medical tools and composite layup tooling.

PC-ABS

PC-ABS is a blend of polycarbonate (PC) and ABS, offering a balance of impact resistance and toughness. It is ideal for prototyping, low-volume production, and industrial applications.

PLA

PLA (Polylactic Acid) is a biodegradable, easy-to-print thermoplastic derived from renewable resources. It is widely used for concept models, prototypes, toys, and decorative objects.

TPU

TPU (Thermoplastic Polyurethane) is an elastomeric material known for its flexibility, durability, and chemical resistance. It is commonly used for medical devices, tooling, and flexible parts.

PETG

PETG (Polyethylene Terephthalate Glycol-modified) is a tough and chemically resistant thermoplastic, ideal for mechanical components, prototypes, and food-safe applications.

FDM Material Properties Compared

Material

Colour

Max. dimensions

Tensile Stress at break (MPa)

Tensile Modulus (GPa)

PEEK

beige

500x500x500 mm

53-95

3.3-3.5

PEEK CF

black

500x500x500 mm

55-125

3.7-10.1

PA12 CF

black

914x609x914 mm

32.7-83.5

3.00-9.46

PA6 CF

black

500x500x500 mm

34-171

2.6-13

ULTEM 9085

natural beige

500x500x500 mm

59-98

2.39-2.9

ULTEM 1010

natural beige

914x609x914 mm

28.2-79.2

3.00-3.04

Onyx

black

330x270x200 mm

37

2.4

Onyx CF

black

330x270x200 mm

800

60

Onyx Flame retardant

black

330x270x200 mm

40

3

Onyx ESD

black

330x270x200 mm

50

4.2

ASA

natural beige, black

914x609x914 mm

28.3-31.9

2.05-2.14

PA6

withish

500x500x500 mm

51-54

1.5-1.6

PC-ABS

black, white

330x240x300 mm

25.9-34.7

1.87-1.99

PP

translucid

500x500x500 mm

16.3-20

0.507-0.532

PLA

multicolor

330x240x300 mm

330x240x300

2.7-3.8

ABS

multicolor

914x609x914 mm

19-38

1.38-2.40

ABS ESD

white, black

600x325x500 mm

19.8-31.8

1.121-2.69

PA12

ivory white

330x240x300 mm

33.4-41.2

1.25-1.51

TPU

translucid

330x240x300 mm

6.4-37.9

0.056-0.067

PETG

multicolor

330x240x300 mm

19-44

1.711-1.874

FDM Surface Finishes

CNC machining

Surface directly obtained from machining without any additional treatments. It features typical tool marks

  • Roughness Ra 3.2 - 6.3 µm
  • See all materials
Dyeing

Very smooth surface obtained through polishing processes. Used to enhance aesthetics and reduce friction.

  • Roughness: Ra 0.2 - 0.8 µm
  • See all materials
Painting

Improved surface over as-machined through additional finishing passes, reducing tool marks.

  • Roughness Ra 1.6 - 3.2 µm
  • See all materials
Vapor Smoothing

Surface with a matte finish characterized by fine, uniform streaks obtained through brushing.

  • Roughness Ra 0.8 - 1.5 µm
  • See all materials

Pros & Cons of FDM 3D Printing

Pros

Wide range of materials with various mechanical properties

Strong and durable parts for functional applications

Large build volumes available for bigger components

Cons

Rough Surface Finish with often visible layer lines and a rough surface, requiring post-processing for improved aesthetics and smoothness

Limited precision and detail with lower resolution compared to other additive technologies like  SLA or PolyJet

Parts are inherently anisotropic due to weak layer adhesion, affecting mechanical properties

Low productivity since printing speed is lower than other additive technologies, and nesting multiple parts within the build volume is not possible

Warping issues depending on material and geometry

FDM capabilities compared with other technologies

Capabilities

Max. Dimensions

Min. Feature Size

Min. wall thickness

Tolerance

Description

SLS

680x380x540 mm

0.8mm

0.7-1.3 mm 

±0.3% (±0.3mm)

Uses a laser to fuse powdered materials layer by layer, ideal for creating durable and complex parts without support structures,  widely employed in aerospace, automotive, and medical industries.

DMLS

500x280x340 mm

0.6-0.8 mm

0.22 mm

±0.25 (≤15mm);
±0.5 (>15mm)

Similar to SLS but uses metal powders, producing high-strength, intricate metal parts suitable for functional prototypes and end-use components in aerospace, medical, and automotive industries.

SLA

1350x750x500 mm

0.2-0.5 mm

1-3 mm

±0.2% (min. 0.2 mm)

Employs a UV laser to cure liquid resin into solid layers, ideal for creating highly detailed, smooth, and intricate parts. Widely used for detailed prototypes and intricate designs in jewelry and dental applications.

MJF

380x284x380 mm

0.5 mm

0.3-0.5 mm

±0.3% (±0.2 mm)

Utilizes multiple jets to apply fusing agents onto powder, which is then fused by heating elements. Delivers high-resolution, functional parts with fast production times, often used in aerospace, automotive, and consumer goods industries.

Polyjet

490x380x200 mm

1.2-2 mm

1 mm

±0.1%

Jetting liquid photopolymer resin and curing it layer by layer with UV light, enabling highly detailed, multi-material parts with diverse properties. Popular in prototyping and complex, color-rich models in medical modeling, consumer goods and electronics fields.

FDM

914x690x914 mm

1.2-1.5 mm

1.5 mm

±0.5% (±0.5 mm)

Uses a heated nozzle to extrude thermoplastic filament layer by layer, ideal for creating durable and functional prototypes. Commonly used in manufacturing, automotive, and consumer products.

DLP

510x280x350 mm

0.5 mm

1 mm

±0.30 mm < 100mm;
±0.3% > 100 mm

Uses a digital light projector to cure liquid resin layer by layer, providing fast and precise prints with high resolution. Commonly used in dental, jewelry, and high-detail prototype applications.

Large Scale

2500x2500x4000 mm

3 mm

-

±5 mm/mtl

Uses a digital light projector to cure liquid resin layer by layer, providing fast and precise prints with high resolution. Commonly used in dental, jewelry, and high-detail prototype applications.

DED

1200x800x600 mm

-

-

-

Uses an electron beam to melt and deposit metal powders or wire, ideal for repairing or adding features to metal parts in aerospace and manufacturing.

Bindet Jet

430x310x150 mm

-

-

±3% mm

Involves depositing a binder material onto a powder bed to form parts, which are then sintered. Useful for producing complex, cost-effective parts, often used automotive, aerospace, and consumer goods industries as well as jewerky.

FAQ about our FDM 3D Printing service

What are the mechanical properties of FDM parts?

They depend on the material: from flexible plastics to rigid structural ones. Functional parts with good tensile and impact resistance.

What are the dimensional tolerances?

Typically ±0.3 mm, but they vary based on geometry and material.

What are the design constraints?

- Minimum Wall Thickness: 0.8 – 1.5 mm recommended
- Support structures required for overhangs >45°
- Limited precision on very small details
- Warping risk for large flat parts with thin walls

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