Manufacturing Excellence

FFF/FDM 3D Printing Services

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

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 FFF/FDM Printers Work

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.

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

Technical Specifications

	FFF/FDM 3D Printing
Lead Times	Standard: 3 – 4 days \| Expedited: as soon as next-day
Standard Accuracy	Typically within +/- a single build layer thickness for the first inch and +/- .002″ for every inch thereafter.
Standard Build Layer Thickness	50-200 microns (depending on material selection).
Build Envelope	Composite Printer: 330x270x200mm (XYZ) \| All Others: 36 x 24 x 36″ (XYZ)
Finish	Painting, inserts (including inside the part-must be reviewed), or vapor smoothing.
Available Fiber Materials	Carbon fiber, Kevlar, HSHT Fiberglass, Fiberglass
Other Materials	Onyx, ABS, ASA, Nylon 12, Nylon 12 CF, Polycarbonate, PC-ISO (medical grade), PC-ABS, Ultem 9085, Ultem 1010

Frequently Asked Questions

What are the design guidelines?

Minimum Wall Thickness

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

Minimum Clearance for Assemblies

0.020″.

Minimum Feature Size

0.020″ (dependent on layer height).

Minimum Hole Diameter

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

Minimum Unsupported Overhang Angle

40 degrees.

What file type is needed to 3D print my parts?

STEP or STL file.

What if I don’t know which material is best for my application?

A3D Manufacturing is staffed with materials science engineers to help you in determining which material is right for your application.

Can A3D ensure my part is a good fit for the FFF/FDM process?

A3D Manufacturing is staffed with applications engineers to help you in determining which process (and potentially post processing) needs you might have for your application.

How are FFF/FDM parts priced?

Price is directly correlated to material consumption, and printer build time. Self-supporting angles help to reduce support structures. Infill selection and layer height also strongly influence both parameters.