Fused deposition modeling: Difference between revisions
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#REDIRECT [[Fused filament fabrication#Fused deposition modeling]] {{R from merge}} {{R to section}} |
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{{Main|3D printing processes}}[[File:Schematic representation of Fused Filament Fabrication 01.png|300px|thumb| In Fused Deposition Modeling a filament '''a)''' of plastic material is fed through a heated moving head '''b)''' that melts and extrudes it depositing it, layer after layer, in the desired shape '''c)'''. A moving platform '''e)''' lowers after each layer is deposited. For this kind of 3D printing technology additional vertical support structures '''d)''' are needed to sustain overhanging parts]] |
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[[File:ORDbot quantum.jpg|thumb|An ORDbot Quantum 3D printer.]] |
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[[File:Hyperboloid Print.ogv|thumb|[[Time-lapse photography|Timelapse]] video of a [[hyperboloid]] object (designed by [[George W. Hart]]) made of [[Polylactic acid|PLA]] using a [[Reprap|RepRap]] "Prusa Mendel" 3D printer for molten polymer deposition.]] |
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'''Fused deposition modeling''' ('''FDM''') is an [[additive manufacturing]] ('''AM''') technology commonly used for modeling, prototyping, and production applications. It is one of the techniques used for [[3D printing]]. |
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FDM works on an "additive" principle by laying down material in layers; a plastic filament or metal wire is unwound from a coil and supplies material to produce a part. Thus, FDM is also known as a solid-based AM technology.<ref>{{cite journal|last1=Taufik|first1=Mohammad|last2=Jain|first2=Prashant K.|title= A Study of Build Edge Profile for Prediction of Surface Roughness in Fused Deposition Modeling|url= http://manufacturingscience.asmedigitalcollection.asme.org/article.aspx?articleid=2475087|journal= Journal of Manufacturing Science and Engineering, Transactions of the ASME|date=2016-01-05|volume=138|issue= 6|pages=061002|doi= 10.1115/1.4032193}}</ref> |
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The technology was developed by [[S. Scott Crump]] in the late 1980s and was commercialized in 1990.<ref>http://rpworld.net/cms/index.php/additive-manufacturing/rp-rapid-prototyping/fdm-fused-deposition-modeling-.html</ref> The term ''fused deposition modeling'' and its abbreviation to ''FDM'' are trademarked by [[Stratasys]] Inc.<ref name=FDMStratasys/><ref name=USPTO/> The exactly equivalent term, '''''[[fused filament fabrication]]''''' ('''''FFF'''''), was coined by the members of the [[RepRap]] project to give a phrase that would be legally unconstrained in its use. It is also sometimes called Plastic Jet Printing (PJP). |
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== History == |
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Fused deposition modeling (FDM) was developed by [[S. Scott Crump]] in the late 1980s and was commercialized in 1990 by [[Stratasys]].<ref name="Auto3D-10">{{cite book |title=Rapid Prototyping |author=Chee Kai Chua |author2=Kah Fai Leong, Chu Sing Lim |year=2003 |publisher=World Scientific |isbn= 9789812381170|page=124 |url=https://books.google.com/books?id=hpNT01xw4EEC&pg=PA124&dq=Stratasys |accessdate=}}</ref> With the expiration of the patent [https://www.google.com/patents/US5121329 US 5121329 A] on this technology there is now a large open-source development community (called [[RepRap]]), as well as commercial and [[DIY]] variants, which utilize this type of 3D printer. This has led to two orders of magnitude price drop since this technology's creation.<ref>{{Cite book |
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| title = A Revolution in the Making |
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| last = Rundle |
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| first = Guy |
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| publisher = Affirm Press |
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| year = 2014 |
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| isbn = 9781922213303 |
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| location = |
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| pages = |
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}}</ref> |
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== Process == |
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[[File:Robot 3D print timelapse on RepRapPro Fisher.webm|thumb|A timelapse video of a robot model (logo of [[Make (magazine)|Make magazine]]) being printed using FDM on a RepRapPro Fisher printer.]] |
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<!-- section prose is mixed up on plastic applicable and metal-applicable; sometimes indicating only one; and has no sources --> |
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FDM begins with a software process which processes an [[STL (file format)|STL file (STereoLithography file format)]], mathematically slicing and orienting the model for the build process. If required, support structures may be generated. The machine may dispense multiple materials to achieve different goals: |
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1. One may use one material to build up the model. |
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2. Use another as a soluble support structure.<ref>http://www.engr.mun.ca/~kmay/CleanStation/MSDSP400SCWaterWorks_US.pdf</ref> |
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3. One could use multiple colors of the same type of thermoplastic on the same model. |
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The model or part is produced by [[Extrusion|extruding]] small flattened strings of molten material to form layers as the material hardens immediately after extrusion from the nozzle. |
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A plastic filament is unwound from a coil and supplies material to an [[3D printer extruder|extrusion nozzle]] which can turn the flow on and off. There is typically an accurately controlled drive that pushes the filament into the nozzle. |
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The nozzle is heated to melt the material. The thermoplastics are heated well past their [[glass transition]] temperature and are then deposited by an extrusion head. |
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The nozzle can be moved in both horizontal and vertical directions by a numerically controlled mechanism. The nozzle follows a tool-path controlled by a [[computer-aided manufacturing]] (CAM) software package, and the part is built from the bottom up, one layer at a time. [[Stepper motors]] or [[servo motors]] are typically employed to move the extrusion head. The mechanism used is often an X-Y-Z rectilinear design, although other mechanical designs such as [[deltabot]] have been employed. |
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Although as a printing technology FDM is very flexible, and it is capable of dealing with small overhangs by the support from lower layers, FDM generally has some restrictions on the slope of the overhang, and cannot produce unsupported [[stalactite]]s. |
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Myriad materials are available, such as [[Acrylonitrile Butadiene Styrene]] (ABS), [[Polylactic acid]] (PLA), [[Polycarbonate]] (PC), [[Polyamide]] (PA), [[Polystyrene]] (PS), [[lignin]], [[rubber]], among many others, with different trade-offs between strength and temperature properties. In addition, even the color of a given [[thermoplastic]] material may affect the strength of the printed object.<ref>{{Cite journal |
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| last = Wittbrodt |
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| first = Ben |
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| last2 = Pearce |
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| first2 = Joshua M. |
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| date = 2015-10-01 |
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| title = The effects of PLA color on material properties of 3-D printed components |
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| url = https://www.academia.edu/19536314/The_Effects_of_PLA_Color_on_Material_Properties_of_3-D_Printed_Components |
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| journal = Additive Manufacturing |
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| volume = 8 |
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| pages = 110–116 |
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| doi = 10.1016/j.addma.2015.09.006 |
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}}</ref> Recently a German company demonstrated for the first time the technical possibility of processing granular [[PEEK]] into filament form and 3D printing parts from the filament material using FDM-technology.<ref name="3D-printing PEEK">{{cite web|title=3dprint.com, PEEK being 3D-printed|url=http://3dprint.com/52713/indmatec-peek-fdm-printing-filament|work=3dprint.com|date=March 21, 2015|accessdate=March 26, 2015}}</ref> |
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During FDM, the hot molten polymer is exposed to air. Operating the FDM process within an [[inert gas]] atmosphere such as [[nitrogen]] or [[argon]] can significantly increase the layer adhesion and leads to improved mechanical properties of the 3D printed objects.<ref>{{cite journal|last1=Lederle|first1=Felix|last2=Meyer|first2=Frederick|last3=Brunotte|first3=Gabriella-Paula|last4=Kaldun|first4=Christian|last5=Hübner|first5=Eike G.|title=Improved mechanical properties of 3D-printed parts by fused deposition modeling processed under the exclusion of oxygen|url=https://link.springer.com/article/10.1007%2Fs40964-016-0010-y|journal=Progress in Additive Manufacturing|date=2016-04-19|volume=1|issue=1-2|pages=3–7|doi=10.1007/s40964-016-0010-y}}</ref> An inert gas is routinely used to prevent oxidation during [[selective laser sintering]]. |
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== Commercial applications == |
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FDM, a prominent form of [[rapid prototyping]], is used for prototyping and rapid manufacturing. Rapid prototyping facilitates iterative testing, and for very short runs, rapid manufacturing can be a relatively inexpensive alternative.<ref>https://books.google.com/books?id=GUhhs3MnQR4C</ref> |
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FDM uses the [[thermoplastics]] PLA, ABS, ABSi, [[polyphenylsulfone]] (PPSF), [[polycarbonate]] (PC), PETG and [[Ultem]] 9085, and among others.<ref>{{Cite web|url=http://www.3dexfilament.co.uk/wholesale|title=3DEX {{!}} Extremely great filament £19.99|website=www.3dexfilament.co.uk|language=en|access-date=2017-02-09}}</ref> These materials are used for their heat resistance properties. Ultem 9085 also exhibits fire retardancy making it suitable for aerospace and aviation applications. |
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FDM is also used in prototyping scaffolds for medical tissue engineering applications.<ref>Ferry Melchels et al 2011 Biofabrication 3 034114 {{doi|10.1088/1758-5082/3/3/034114}}</ref> |
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==Free applications== |
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[[File:RepRap 'Mendel'.jpg|thumb|left|RepRap version 2.0 (Mendel)]] |
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[[File:Fab@Home Model 2 3D printer.jpg|thumb|[[Fab@Home]] Model 2 (2009)]] |
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[[File:Printing in progress in a 3D printer.webm|thumb|Printing in progress in a [[Ultimaker]] 3D printer during Mozilla Maker party, Bangalore]] |
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[[File:Airwolf 3d Printer.jpg|thumb|left|[[Airwolf 3D]] AW3D v.4 (Prusa)]] |
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Several projects and companies are making efforts to develop affordable 3D printers for home desktop use. Much of this work has been driven by and targeted at [[Do it yourself|DIY]]/enthusiast/[[early adopter]] communities, with additional ties to the academic and [[Hacker (hobbyist)|hacker]] communities.<ref name="Auto3D-26" /> |
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[[RepRap]] is one of the longest running projects in the desktop category. The RepRap project aims to produce a [[free and open source hardware]] (FOSH) 3D printer, whose full specifications are released under the [[GNU General Public License]], and which is capable of replicating itself by printing many of its own (plastic) parts to create more machines.<ref name="AutoSQ-20"/><ref name="AutoSQ-21"/> RepRaps have already been shown to be able to print [[circuit board]]s<ref name="AutoSQ-22"/> and metal parts.<ref name="AutoSQ-23"/><ref name="AutoSQ-24"/><br /> [[Fab@Home]] is the other [[Open-source hardware|opensource hardware]] project for [[Do it yourself|DIY]] 3D printers. |
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Because of the FOSH aims of [[RepRap]], many related projects have used their design for inspiration, creating an ecosystem of related or derivative 3D printers, most of which are also open source designs. The availability of these open source designs means that variants of 3D printers are easy to invent. The quality and complexity of printer designs, however, as well as the quality of kit or finished products, varies greatly from project to project. This rapid development of open source 3D printers is gaining interest in many spheres as it enables hyper-customization and the use of [[public domain]] designs to fabricate [[open source appropriate technology]]. This technology can also assist initiatives in [[sustainable development]] since technologies are easily and economically made from resources available to local communities.<ref name="Auto3D-27" /><ref name="AutoSQ-25"/> |
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==Cost of 3D printer== |
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The cost of 3D printers has decreased dramatically since about 2010, with machines that used to cost $20,000 now costing less than $1,000.<ref name="AutoSQ-26"/> For instance, as of 2017, several companies and individuals are selling parts to build various [[RepRap]] designs, with prices starting at about {{£|99}} / {{US$|100}}<ref name="printerlist" /><ref>{{cite web|title=STARTT 3D Printer|url=https://www.imakr.com/us/en/startt-affordable-3d-printer/1146-startt-3d-printer.html|website=iMakr|accessdate=24 October 2017|ref=STARTT_3D_Printer|language=en}}</ref>. The best selling desktop FDM printer<ref>{{cite web|title=3D Printing Trends Q3/2017|url=https://www.3dhubs.com/s3fs-public/3d-printing-trends-Q3-2017.pdf#page=4|website=3dhubs.com|accessdate=24 October 2017|ref=3dtrends}}</ref>, [[Prusa i3|Prusa i3 MK2]], costs {{US$|900}} assembled or {{US$|600}} for self-assembly kit<ref>{{cite web|title=Prusa Research s.r.o. Shop|url=https://shop.prusa3d.com/en/17-3d-printers|website=shop.prusa3d.com|accessdate=24 October 2017|ref=shop_prusa3d}}</ref>. |
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The open source [[Fab@Home]] project<ref name="fabathome" /> has developed printers for general use with anything that can be squirted through a nozzle, from chocolate to silicone sealant and chemical reactants. Printers following the project's designs have been available from suppliers in kits or in pre-assembled form since 2012 at prices in the US$2000 range. |
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The [[LulzBot]] 3D printers manufactured by [[Aleph Objects]] are another example of an open-source application of fused deposition modeling technology. The flagship model in the LulzBot line, the TAZ printer takes inspiration for its design from the RepRap Mendel90 and [[Prusa i3]] models. The LulzBot 3D printer is currently the only printer on the market to have received the "Respects Your Freedom" certification from the [[Free Software Foundation]].<ref>{{cite web|last1=Gay|first1=Joshua|title=Aleph Objects|url=http://www.fsf.org/resources/hw/endorsement/aleph-objects|website=fsf.org|publisher=Free Software Foundation, Inc.|accessdate=2 April 2015|date=29 Apr 2013}}</ref> |
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==See also== |
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* [[3D printing]] |
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* [[3D printer extruder]] |
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* [[Direct metal laser sintering]] |
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* [[Fab lab]] |
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* [[Fab@Home]] |
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* [[Fused filament fabrication]] |
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* [[G-code]] |
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* [[Hyrel 3D]] |
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* [[MakerBot Industries]] |
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* [[Printrbot]] |
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* [[Prusa i3]] |
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* [[Rapid prototyping]] |
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* [[RepRap Project]] |
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* [[Robo 3D]] |
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* [[Selective laser sintering]] |
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* [[Stereolithography]] |
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* [[Ultimaker]] |
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* [[Von Neumann universal constructor]] |
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== References == |
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{{Reflist|2|refs= |
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<ref name="Auto3D-26">{{ cite web | url = http://www.npr.org/templates/story/story.php?storyId=131644649 | title = A Space For DIY People To Do Their Business (NPR.org, November 28, 2010) | first = Jon | last=Kalish | accessdate = 2012-01-31 }}</ref> |
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<ref name="AutoSQ-20">Jones, R., Haufe, P., Sells, E., Iravani, P., Olliver, V., Palmer, C., & Bowyer, A. (2011). Reprap-- the replicating rapid prototyper. Robotica, 29(1), 177-191.</ref> |
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<ref name="AutoSQ-21">{{ cite web | url = http://www.computerworld.co.nz/article/495672/open_source_3d_printer_copies_itself/ | title = Open source 3D printer copies itself | publisher = Computerworld New Zealand | date = 2008-04-07 | accessdate = 2013-10-30 }}</ref> |
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<ref name="AutoSQ-22">[http://blog.reprap.org/2009/04/first-reprapped-circuit.html RepRap blog 2009 visited 2/26/2014]</ref> |
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<ref name="AutoSQ-23">[https://www.nytimes.com/2013/12/10/science/an-inexpensive-way-to-print-out-metal-parts.html?_r=0 An Inexpensive Way to Print Out Metal Parts - The New York Times]</ref> |
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<ref name="AutoSQ-24">[http://ieeexplore.ieee.org/xpl/articleDetails.jsp?tp=&arnumber=6678531&queryText%3Dopen+source+3d+metal+printer Gerald C. Anzalone, Chenlong Zhang, Bas Wijnen, Paul G. Sanders and Joshua M. Pearce, " Low-Cost Open-Source 3-D Metal Printing" ''IEEE Access'', 1, pp.803-810, (2013). doi: 10.1109/ACCESS.2013.2293018]</ref> |
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<ref name="Auto3D-27">{{ cite web | url = http://www.ccsenet.org/journal/index.php/jsd/article/view/6984 | title = 3-D Printing of Open Source Appropriate Technologies for Self-Directed Sustainable Development (Journal of Sustainable Development, Vol.3, No. 4, 2010, pp. 17–29) | first = Joshua M. | last = Pearce | accessdate = 2012-01-31 |display-authors=etal}}</ref> |
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<ref name="AutoSQ-25">[http://techfortrade.org/our-initiatives/3d4d-challenge/ Tech for Trade, 3D4D Challenge] {{webarchive|url=https://web.archive.org/web/20141227200348/http://techfortrade.org/our-initiatives/3d4d-challenge/ |date=2014-12-27 }}</ref> |
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<ref name="AutoSQ-26">[http://bits.blogs.nytimes.com/2013/02/17/disruptions-3-d-printing-is-on-the-fast-track/?nl=todaysheadlines&emc=edit_th_20130218 Disruptions: 3-D Printing Is on the Fast Track – NYTimes.com]</ref> |
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<ref name="printerlist">{{ cite web | author = www.3ders.org | url = http://www.3ders.org/pricecompare/3dprinters/ | title = 3D printers list with prices | publisher = 3ders.org | accessdate = 2013-10-30 }}</ref> |
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<ref name="fabathome">[https://www.newscientist.com/article/dn10922-desktop-fabricator-may-kickstart-home-revolution.html New Scientist magazine: Desktop fabricator may kick-start home revolution, 9 January 2007]</ref> |
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<ref name="FDMStratasys">{{ cite web | author = www.stratasys.com | url = http://www.stratasys.com/legal/legal-information | title = Stratasys Legal Information | publisher = stratasys.com | accessdate = 2016-07-20 }}</ref> |
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<ref name="USPTO">{{ cite web | author = uspto.gov | url = http://tsdr.uspto.gov/#caseNumber=4325106&caseSearchType=US_APPLICATION&caseType=DEFAULT&searchType=statusSearch | title = Trademark Status Document Retrieval (TSDR) | publisher = uspto.gov | accessdate = 2017-08-20 }}</ref> |
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}} |
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== Further reading == |
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* {{cite web|title=Results of Make Magazine's 2015 3D Printer Shootout|url=https://docs.google.com/spreadsheets/d/1EKsDga2PVD_H9HI2MJbPXCey6bYFEIWErOsAHKHZ3GU/edit#gid=1210667708|publisher=docs.google.com|accessdate=1 June 2015}} |
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* {{cite web|title=Evaluation Protocol for Make Magazine's 2015 3D Printer Shootout|url=http://makezine.com/2014/11/07/how-to-evaluate-the-2015-make-3dp-test-probes/|publisher=makezine.com|accessdate=1 June 2015}} |
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* {{cite journal|last=Stephens|first=Brent|author2=Parham Azimia |author3=Zeineb El Orcha |author4=Tiffanie Ramos |title=Ultrafine Particle Emissions from Desktop 3D Printers|journal=Atmospheric Environment|date=November 2013|volume=79|pages=334–339|doi=10.1016/j.atmosenv.2013.06.050|url=http://www.sciencedirect.com/science/article/pii/S1352231013005086|accessdate=13 August 2013}} |
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* {{cite web|title=How Fused Deposition Modeling Works |url=https://thre3d.com/how-it-works/material-extrusion/fused-deposition-modeling-fdm |publisher=THRE3D.com |accessdate=7 February 2014 |deadurl=yes |archiveurl=https://web.archive.org/web/20140221050642/https://thre3d.com/how-it-works/material-extrusion/fused-deposition-modeling-fdm |archivedate=February 21, 2014 }} |
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* {{cite web|title=3D Printing process and How FDM technology works Video|url=http://homeshop3dprinting.com/3d-printing-qa/3d-printing-process-and-technologies/|publisher=homeshop3dprinting.com|accessdate=4 June 2014}} |
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* {{cite web|title=Complete list of G-code used by 3D printer's firmware of RepRap project|url=http://reprap.org/wiki/G-code|publisher=RepRap.org|accessdate=26 August 2015}} |
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{{3d printing}} |
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{{DEFAULTSORT:Fused Deposition Modeling}} |
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[[Category:Fused filament fabrication]] |
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[[Category:American inventions]] |
[[Category:American inventions]] |
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[[Category:Articles containing video clips]] |
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[[Category:1990 introductions]] |
[[Category:1990 introductions]] |
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[[Category:1990 establishments in the United States]] |
[[Category:1990 establishments in the United States]] |
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