Fused Deposition Fused Deposition ModelingModeling

DefinitionDefinition

Fused Deposition Modeling (FDM) is a extrusion-based rapid prototyping process, it has been used in conjunction with stereolithograghy and laser sintering.

HistoryHistory

FDM was developed by Stratasys, Inc. of Eden Prairie, MN in the early 1990’s.

It was created as a concept modeling device, but is now used more for creating casting masters and direct use prototyping.

HistoryHistory

FDM has evolved thru several models beginning with the original 3-D modeler which was a floor unit. They have progressed thru various desktop units.

SpecsSpecs

The 1500-2000 models are capable of building parts in the 10” x 10” x 10” range where as the 8000 and Quantum model can build 24” x 20” x 24” parts.

A newly released water soluble support material which allows for more complex geometry where complicated support structures can now be flushed away with a water based solution.

Build MaterialsBuild Materials The FDM’s can be equipped to build with

investment casting wax, acrylonitrile butadiene styrene (ABS) plastic, medical grade ABS thermoplastic, and or Elastomer.

The build and support materials come in filament form, about 0.070” in diameter, rolled on spools.

The spools mount on a spindle in the rear of the machine, and the filament feeds thru a flexible tube attached to the back of the extrusion head.

New technologies in the ceramics industry involve base material research.

More About the FilamentMore About the Filament http://www.emeraldinsight.comhttp://www.emeraldinsight.com

More About the FilamentMore About the Filament A new binder formulation for fused deposition of A new binder formulation for fused deposition of

ceramics (FDC) has been developed. This material is ceramics (FDC) has been developed. This material is formulated entirely from commercially available formulated entirely from commercially available constituents, and performs well in FDC applications. constituents, and performs well in FDC applications. In addition to adequate FDC properties, the binder In addition to adequate FDC properties, the binder shows good thermal decomposition behavior for shows good thermal decomposition behavior for binder removal. As a result, several complex PZT binder removal. As a result, several complex PZT samples have been fabricated using FDC. This samples have been fabricated using FDC. This formulation shows promise for use in conjunction formulation shows promise for use in conjunction with FDC of functional piezoelectric ceramic with FDC of functional piezoelectric ceramic transducers and actuators. Since the exact transducers and actuators. Since the exact formulation is known, this material should be easily formulation is known, this material should be easily adaptable to other fillers such as stainless steel, adaptable to other fillers such as stainless steel, aluminum oxide, or silicon nitride. aluminum oxide, or silicon nitride.

More About the FilamentMore About the Filament

The quality of the feed filament The quality of the feed filament is one of the most important is one of the most important parameters for successful FDC. parameters for successful FDC.

The critical properties for high The critical properties for high quality feed filaments include:quality feed filaments include:

o viscosityviscosityo strengthstrengtho modulusmodulus

Extrusion HeadExtrusion Head

The extrusion head is the key to FDM technology. It consists of:

Drive Wheels Drive Blocks Heating Chamber Tips Filament

Extrusion HeadExtrusion Headwww.csa.comwww.csa.com

Click here to view FDM macClick here to view FDM machines at the hines at the

www.stratasys.comwww.stratasys.com site. site.

FDM OperationFDM Operation Before building the STL file has to be converted

into the machine language which is done by the Quick-Slice software.

The STL file is read into Quick-Slice and is displayed graphically on the screen in the Cartesian coordinate system.

This software allows you to choose slice layer thickness, the build and support materials, as well as the tip sizes.

Then the part must be scaled to fit the bounding box size, and oriented at the optimum build position.

FDM OperationFDM Operation

Once the part has been oriented and scaled, it must be sliced.

The slice range is from 0.005” to 0.015”.

The rest of the build parameters are default by the Quick-Slice software but can be changed manually .

Typical Uses of FDM Typical Uses of FDM PartsParts

Concept/Design Visualization Direct use components Investment casting Medical applications- results show

that FDM allows the design and fabrication of highly reproducible bioresorbable 3D scaffolds with a fully interconnected pore network.

Flexible components

AdvantagesAdvantages

The strength and temperature capability of the build material.

Safe laser free operation.Easy post processing with the new water soluble support material.

DisadvantagesDisadvantages

Slower than laser based systems

Small features like a vertical thin column prove difficult to build with FDM.

Materials ResearchMaterials Research Ceramics are the newest thing in fully Ceramics are the newest thing in fully

functional working products from a RP functional working products from a RP perspective.perspective.

Glass fibers were found to significantly Glass fibers were found to significantly improve the strength of an ABS filament improve the strength of an ABS filament at the expense of reduced flexibility and at the expense of reduced flexibility and handle-ability. handle-ability.

The latter two properties of glass fiber The latter two properties of glass fiber reinforced ABS filaments were improved reinforced ABS filaments were improved by adding a small amount of plasticizer by adding a small amount of plasticizer and compatibilizer. and compatibilizer.

Hospital UseHospital Use

This new manufacturing device uses This new manufacturing device uses a photocurable monomer, hardened a photocurable monomer, hardened by a UV-laser. The spatial resolution by a UV-laser. The spatial resolution of the system is about 0.1 mm. 3D-of the system is about 0.1 mm. 3D-reconstructions were performed on reconstructions were performed on a personal computer. a personal computer.

Future ApplicationsFuture Applications

Three-dimensional honeycomb, which Three-dimensional honeycomb, which were formed via the FD technique, were formed via the FD technique, showed excellent electromechanical showed excellent electromechanical properties for transducer applications. properties for transducer applications.

Highly efficient ceramics for electrical Highly efficient ceramics for electrical transfer purposestransfer purposes

Accurate bio-safe replacement body Accurate bio-safe replacement body parts for our troops and victims of parts for our troops and victims of senseless violence. senseless violence.

ReferencesReferences

Rapid Prototyping Technology by Kenneth G. Cooper

http://www.mec.cf.ac.uk/services/?viehttp://www.mec.cf.ac.uk/services/?view=fdm&style=plainw=fdm&style=plainwww.csa.com/partners/viewrecordwww.csa.com/partners/viewrecordwww3.interscience.wiley.comwww3.interscience.wiley.comwww.blackwell-synergy.comwww.blackwell-synergy.comJournal of the American Ceramic Journal of the American Ceramic

Society Society www.emeraldinsight.comwww.emeraldinsight.com