Fused Deposition Modelling (FDM)

Principle:
The principle of the FDM is based on surface chemistry, thermal energy, and layer manufacturing
technology. The material in filament (spool) form is melted in a specially designed head, which
extrudes on the model. As it is extruded, it is cooled and thus solidifies to form the model. The
model is built layer by layer, like the other RP systems. Parameters which affect performance and
functionalities of the system are material column strength, material flexural modulus, material
viscosity, positioning accuracy, road widths, deposition speed, volumetric flow rate, tip diameter,
envelope temperature, and part geometry.

Process:
1. The modeling material is in spools — very much like a fishing line.
2. The filament on the spools is fed into an extrusion head and heated to a semi-liquid state.
3. The semi-liquid material is extruded through the head and then deposited in ultra thin layers
from the FDM head, one layer at a time.
4. Since the air surrounding the head is maintained at a temperature below the materials’
melting point, the exiting material quickly solidifies.
5. Moving on the X–Y plane, the head follows the tool path generated by QuickSlice® or Insight
generating the desired layer.
6. When the layer is completed, the head moves on to create the next layer. The horizontal
width of the extruded material can vary between 0.250 to 0.965 mm depending on model.
7. This feature, called “road width”, can vary from slice to slice. Two modeler materials are
dispensed through a dual tip mechanism in the FDM machine.
8. A primary modeler material is used to produce the model geometry and a secondary
material, or release material, is used to produce the support structures.
9. The release material forms a bond with the primary modeler material and can be washed
away upon completion of the 3D models.
Advantages:
(1) Fabrication of functional parts- FDM process is able to fabricate prototypes with materials that
are similar to that of the actual molded product.

(2) Minimal wastage- The FDM process build parts directly by extruding semi-liquid melt onto the
model.

(3) Ease of support removal- With the use of Break Away Support System (BASS) and Water Works
Soluble Support System, support structures generated during the FDM building process can be easily
broken off or simply washed away.

(4) Ease of material change- Build materials, supplied in spool form (or cartridge form in the case of
the Dimension or Prodigy Plus), are easy to handle and can be changed readily when the materials in
the system are running low.

Disadvantages:
(1) Restricted accuracy- Parts built with the FDM process usually have restricted accuracy due to the
shape of the material used, i.e., the filament form.

(2) Slow process. The building process is slow, as the whole cross-sectional area needs to be filled
with building materials.

(3) Unpredictable shrinkage- As the FDM process extrudes the build material from its extrusion head
and cools them rapidly on deposition, stresses induced by such rapid cooling invariably are
introduced into the model.

Applications:
(1) Models for conceptualization and presentation. Models can be marked, sanded, painted and
drilled and thus can be finished to be almost like the actual product.

(2) Prototypes for design, analysis and functional testing. The system can produce a fully functional
prototype in ABS. The resulting ABS parts have 85% of the strength of the actual molded part. Thus
actual testing can be carried out, especially with consumer products.

(3) Patterns and masters for tooling. Models can be used as patterns for investment casting, sand
casting and molding.
 Laminated Object Manufacturing (LOM)
Principle:
(1) Parts are built, layer-by-layer, by laminating each layer of paper or other sheet-form materials
and the contour of the part on that layer is cut by a CO2 laser.

(2) Each layer of the building process contains the cross-sections of one or many parts. The next
layer is then laminated and built directly on top of the laser-cut layer.

(3) The Z-control is activated by an elevation platform, which lowers when each layer is completed,
and the next layer is then laminated and ready for cutting. The Z-height is then measured for the
exact height so that the corresponding cross sectional data can be calculated for that layer.

(4) No additional support structures are necessary as the “excess” material, which are cross-hatched
for later removal, act as the support.

Process:
The process consists of three phases: pre-processing, building and post-processing.
Pre-processing - The pre-processing phase comprises several operations. The initial steps include
generating an image from a CAD-derived STL file of the part to be manufactured, sorting input data,
and creating secondary data structures.

Building - In the building phase, thin layers of adhesive-coated material are sequentially bonded to
each other and individually cut by a CO2 laser beam. The build cycle has the following steps:

(1) LOM creates a cross-section of the 3D model measuring the exact height of the model and slices
the horizontal plane accordingly. The software then images crosshatches which define the outer
perimeter and convert these excess materials into a support structure.

(2) The computer generates precise calculations, which guide the focused laser beam to cut the
cross-sectional outline, the cross- hatches, and the model’s perimeter. The laser beam power is
designed to cut exactly the thickness of one layer of material at a time. After the perimeter is
burned, everything within the model’s boundary is “freed” from the remaining sheet.

(3) The platform with the stack of previously formed layers descends and a new section of material
advances. The platform ascends and the heated roller laminates the material to the stack with a
single reciprocal motion, thereby bonding it to the previous layer.

(4) The vertical encoder measures the height of the stack and relays the new height to LOM, which
calculates the cross section for the next layer as the laser cuts the model’s current layer.
Post-processing - The last phase, post-processing, includes separating the part from its support
material and finishing it. The separation sequence is as follows:

(1) A forklift may be needed to remove the larger and heavier parts from the LOM.

(2) Normally a hammer and a putty knife are all that is required to separate the LOM block from the
platform. However, a live thin wire may also be used to slice through the double-sided foam tape,
which serves as the connecting point between the LOM stack and the platform.

(3) The surrounding wall frame is lifted off the block to expose the crosshatched pieces of the excess
material. Crosshatched pieces may then be separated from the part using wood carving tools.
System Structure:
1. Lamination is accomplished by applying heat and pressure by way of rolling a heated
cylinder across the sheet of material, which has a thin layer of a thermoplastic adhesive
on one side.
2. Studies have indicated that interlaminate strength of LOM parts is a complex function of
bonding speed, sheet deformation, roller temperature, and contact area between the
paper and the roller.
3. By increasing pressure of the heated roller, lamination is improved due to fewer air
bubbles.
4. The material supply and take-up system comprises two material roll supports (supply
and rewind), several idle rollers to direct the material, and two rubber-coated nip-rollers
(driving and idle), which advance or rewind the sheet material during the preprocessing
and building phases.
5. To make material flow through the LOM systems more smoothly, mechanical nip rollers
are used.

Materials:
It has been demonstrated that plastics, metals, and even ceramic tapes can be used. However, the
most popular material has been Kraft paper with a polyethylene-based heat seal adhesive system
because it is widely available and cost-effective.

Advantages:
1. Wide variety of materials
2. Fast build time
3. High precision
4. No external Support structure required
Disadvantages:
1. Precise power adjustment required
2. Fabrication of thin walls
3. Integrity of prototypes
4. Removal of supports

Applications:
1. Visualization purposes
2. Form, fit and function
3. Manufacturing of parts
4. Rapid tooling