FFF/FDM 3D Printing

When strength is the priority, fused filament fabrication (FFF) or fused deposition modeling (FDM) is an option for creating robust and accurate parts

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fff and fdm 3d printing services

3D Printing Strong, End-Use Parts

A traditional 3D printing process using layers of thermoplastic filament to create durable, lasting parts

Our FFF/FDM capabilities combine large build volumes with specialized materials, allowing you to produce a wide range of functional parts.

From small fixtures to large aerospace prototypes, there is a 3D printer and material to fit your project's specific needs.

How it Works

An overview of the fused filament fabrication printing process

To begin the FDM/FFF process, a CAD file is sliced into layers using software that communicates where material needs to be extruded on each layer.

There are two types of material for this: support material and actual part material.

Once the layer receives the sliced file, printing begins by heating the filament and extruding it layer by layer. After the part is made, the support material must be removed manually or with a solution.

fff and fdm 3d printing services
fff and fdm 3d printing services


Explore popular uses for FFF/FDM 3D printing

  • Manufacturing aids: jigs, fixtures, drill guides, locating tools, go/no-go gauges
  • Large, flat parts
  • For applications where thermoplastics are essential to function
  • Robust prototypes



Continuous fibers enable our composite printers to print metal-strength parts. They cannot be used alone — however, when printed with a composite base, they form the backbone of a strong printed part.

Fibers include:

  • Carbon fiber
  • Kevlar
  • HSHT Fiberglass
  • Fiberglass
  • Onyx - Nylon 6 with short chop CF strands
  • ABS
  • ASA
  • Nylon 12
  • Nylon 12 CF
  • PC (Polycarbonate)
  • PC-ISO (medical grade)
  • PC-ABS
  • Ultem 9085
  • Ultem 1010


  • Standard: 3 – 4 days
  • Expedited: as soon as next-day

Typically within +/- a single build layer thickness for the first inch and +/- .002” for every inch thereafter.

50-200 microns (depending on material selection).

  • Composite Printer: 330x270x200mm (XYZ)
  • All Others: 36 x 24 x 36” (XYZ)

Depending on material selected, options include: painting, inserts (including inside the part-must be reviewed), or vapor smoothing.


0.040” is commonly accepted (dependent on material and nozzle size).


0.020” (dependent on layer height).

0.060” for X/Y axis; 0.040” for Z axis.

40 degrees.


Gain answers to common questions about the FFF/FDM 3D printing process.

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