Technical Description of a Fused Filament

Fabrication 3D Printer
What is 3D Printing?
In a world where technology is
ever changing, rapid
prototyping using three-
dimensional (3D) printing has
become an important tool in
product design and
manufacturing. 3D printing or
additive manufacturing is the
process of creating a 3D object
in which layers of material are
added on to each other. Objects Image from
http://uk.rsonline.com/web/generalDisplay.html
are generated using computer
software, such as slicing software and computer aided design software, and
are transmitted to a 3D printer that prints the object path. Almost any shape
or geometry can be created using 3D printing. Sometimes, 3D printing can
produce parts faster and less expensive than contemporary methods, like
injection molding. The most common type of 3D printing on the market today
is fused filament fabrication (FFF) 3D printing that uses material extrusion.

Components of a 3D Printer
Filament
There are two main consumables used in FFF 3D printing: polylactic acid
(PLA) and acrylonitrile butadiene styrene (ABS). The main differences
between the two materials is that PLA can be used without a heated printing
bed, while ABS is used with a heated printing bed. ABS is a more ductile and
can be post processed to create a glossy finish. When used in FFF 3D
printing, the two materials are fed though an extruder to the printing bed.
Extruder
The extruder is a core component to a 3D printer. This apparatus is where
the filament is fed through, heated, and pushed out onto the printing bed.
There are two main parts of the extruder: cold end and hot end. The cold end
is where the motor draws in the filament and the hot end is where the
filament is heated and pushed out.
Heater Block & Thermistor
The heater block heats the plastic as it travels through the extruder. The
thermistor is a sensor that helps determine the temperature of the hot end of
the extruder.
Nozzle

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The nozzle is a piece attached to the end of the extruder where the filament
gets pushed out of. Nozzles determine the diameter of the filament when it
exits the extruder. Different size nozzles can be used to change the diameter
of the filament. One of the most common issues with 3D printers is clogged
nozzles.

Cooling Fan
The cooling fan cools off the plastic on the printed object after it get
deposited from the nozzle. This fan helps the object maintain its final shape.
Printing Bed
A printing bed is the surface where the heated plastic from the extruder is
deposited. This area is where the plastic is built up layer by layer until an
object is created. Once the object is done printing, it is peeled off of the
surface.
Printing Surfaces
The surfaces used in 3D printing are important so that the 3D object
does not stick to the printing bed and can be easily removed once it is
complete. Surfaces depend on the type of material being printed.
Heated vs. Non-Heated
Heated printing bed help prevent the object from warping during
printing. Plastic shrinks slightly as it cools, which causes the object to
warp near the edges and peel off. If the printer uses PLA, it does not
need a heated printing bed because it is minimally affected by
warping.

Motion Control
Cartesian
This method of motion control
utilizes the X, Y, and Z axes
(Cartesian coordinates
system). The build area is
typically a rectangular shape.
Delta
This method of motion control
has three arms that come
together in the center of the
printer. Delta style also uses

Image from
http://pintstein.wordpress.com/2016/01/22/delta-printer-
experience/
a Cartesian coordinate system, but all three arms move at the same time to
navigate the path.

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Stepper Motors
These motors are the center of how the printer moves. They rotate
continuously in precise increments. This type of motor allows for precise
control of motion so that complex patterns can be made in the X, Y, and Z
directions. Common 3D printers use motors that move 200 steps per
revolution.

Process of 3D Printing
Modeling
The first step in 3D printing is modeling, where digital models are created
using computer aided design (CAD). This helps modify and verify designs
before printing, saving material and time. Geometric data is prepared via 3D
scanning where data is collected based on the shape and appearance of the
real object.

Printing
After 3D models are prepared, they are converted into an STL file. The file is
then examined for possible production errors like holes, self-intersections,
and face normals. Once an STL file is completed, it is processed using slicing
software which converts the model data into a series of layers. A key part of
slicing is adding internal supports and rafts. The two components are
important in maintaining the object shape during printing so that layers do
not collapse. This processes produces G-Code, a series of instructions
generated to print the object.
One important aspect of 3D printing is printer resolution. Resolution
describes the layer thickness in the X-Y direction. Layer thickness is usually
around 100 micrometers, but some printers can print layers that are even
smaller.

After all settings and preparations are completed, printing begins. The
filament set on a spool is led through the cold end of the extruder and is then
pinched to feed precise amounts. Once the filament reaches the hot end, it is
heated from the heater block and is forced out of the nozzle onto the print
bed. While the filament is being deposited, the extruder is moving according
the G-Code generated by the slicing software.

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Finishing
After an object is finished being
printed, it can be further Image from https://3dprint.com/82272/what-3d-
improved using finishing. 3D printing-works/
printed objects can become
more precise using a
combination of additive
manufacturing and subtractive
manufacturing. After an object
is printed using standard
processes, material can be
removed to create a more
realistic version of the 3D
model. Objects made from ABS
can also be improved using
chemical vapor processes using acetone or sanded using 100 200 grit
sandpaper. Some objects are printed using internal supports to create
vertical holes or hanging horizontal bars greater than 45 degrees from
vertical. These supports are made from a sacrificial plastic and need to be
removed after printing is completed.

Conclusion
3D printing is an exciting an innovative process. In fused filament fabrication
3D printing, plastic is fed through and extruder, heated, and deposited onto
the printing bed after receiving signals from digital modeling. This process
can create so many complex objects and patterns. Future research and
development in 3D printing will help reshape the manufacturing and product
design industries.