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Fused Deposition Modeling (FDM) 3D Printing
General Purpose Prototypes & Production Parts
High accuracy, large format FDM 3D printing. Build end-use parts up to 36 x 24 x 36 inches in a single print.
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Fused Deposition (FDM) 3D Printing
Production Grade Thermoplastics
What is Fused Deposition Modeling?
Forge Labs offers a wide range of advanced thermoplastics identical to those used in traditional manufacturing processes, making it ideal for end-use parts, testing real-world material properties, or creating durable jigs, fixtures, and templates for production. FDM offers 14 unique 3D printed materials making it one of the versatile technologies suitable for a number of specialized applications such as medical devices, electric static dissipative parts, or high temperature applications where Flame, Smoke Toxicity (FST) ratings are critical.
Manufacture using FDM 3D Printing Services when you need strong, functional parts that are dimensionally stable, and don't mind some visible layer lines. Parts are produced on Stratasys Fortus series machines which offer the industry's best accuracy and part repeatability along with one of the commercially largest printing envelopes on the market. Manufacture large, complex designs in a wide range of thermoplastics up to 36 x 24 x 36 inches in a single build with strength and accuracy that only Stratasys FDM machines can provide.
What is Fused Deposition Modeling (FDM)?
Forge Labs offers a wide range of advanced thermoplastics identical to those used in traditional manufacturing processes, making it ideal for end-use parts, testing real-world material properties, or creating durable jigs, fixtures, and templates for production. FDM offers 14 unique 3D printed materials making it one of the versatile technologies suitable for a number of specialized applications such as medical devices, electric static dissipative parts, or high temperature applications where Flame, Smoke Toxicity (FST) ratings are critical.
Manufacture using FDM 3D Printing Services when you need strong, functional parts that are dimensionally stable, and don't mind some visible layer lines. Parts are produced on Stratasys Fortus series machines which offer the industry's best accuracy and part repeatability along with one of the commercially largest printing envelopes on the market. Manufacture large, complex designs in a wide range of thermoplastics up to 36 x 24 x 36 inches in a single build with strength and accuracy that only Stratasys FDM machines can provide.
36" x 24"
Max X/Y Build Volume
± 0.15
MM Part Tolerances
14
High Performance Materials
2-5 Day
Average Lead Time
36" x 24"
Max X/Y Build Volume
± 0.15
MM Part Tolerances
12
High Performance Materials
2-5 Day
Average Lead Time
Materials| Fused Deposition Modeling
ABS
UV Resistant
Flexible
Rigid
Performance
High Temperature
ABS-M30
Strongest Additive ABS Thermoplastic
ABS-M30™ by Stratasys is up to 70 percent stronger than standard ABS, providing significantly better layer bonding, impact resistance and flextural strength than standard level consumer grade ABS. ABS-M30 highly cost effective solution, ideal material for numerous applications including conceptual modeling, functional prototyping, manufacturing tools such as jigs and fixtures as well as end-use production parts.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength, Yield | 32 MPa | ASTM D638 |
Tensile Modulus | 2,230 MPa | ASTM D638 |
Elongation at Break | 4% | ASTM D648 |
Unnotched Izod Impact | 283 J/m | ASTM D256 |
Heat Deflection Temperature | 86°C @ 0.45 MPa | ASTM D648 |
PC-ABS
Strength, Heat Resistance & Flexibility
Polycarbonate-ABS (PC-ABS) combines the desirable strength and heat resistant properties of PC with the flexibility & cost advantages of ABS. PC-ABS is one of the most widely used thermoplastics used in automotive, electronics and variety of other industrial manufacturing applications.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength, Yield | 41 MPa | ASTM D638 |
Tensile Modulus | 1,900 MPa | ASTM D638 |
Elongation at Break | 6% | ASTM D648 |
Unnotched Izod Impact | 481 J/m | ASTM D256 |
Heat Deflection Temperature | 110°C @ 0.45 MPa | ASTM D648 |
ABS ESD7
Static Dissipative
ABS thermoplastic with static dissipative properties (ABS-ESD7) is ideal for applications where a static charge can damage products, impair their performance or cause an explosion. ABS-ESD7 prevents static electricity build up so that it will not produce static shock while also preventing fine powders & dust from sticking. ABS-ESD7 is widely used in electronic manufacturing industries for creating jigs and fixtures, enclosures and packaging.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength | 35 MPa | ASTM D638 |
Tensile Modulus | 2,400 MPa | ASTM D638 |
Elongation at Break | 3.4% | ASTM D638 |
Unnotched Izod Impact | 55 J/m | ASTM D256 |
Heat Deflection Temperature | 96°C @ 0.45 MPa | ASTM D648 |
ASA
UV Stable ABS Thermoplastic
ASA provides the same mechanical properties as ABS-M30 along with enhanced UV stability, making it ideal for outdoor applications. Combined with good impact resistance, toughness and aesthetics, ASA is one of the most broadly used thermoplastics, ideal for concept models, functional production parts such as jigs, fixtures, working prototypes and manufacturing tools.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength | 33 MPa | ASTM D638 |
Tensile Modulus | 2,010 MPa | ASTM D638 |
Elongation at Break | 5.9% | ASTM D638 |
Unnotched Izod Impact | 285 J/m | ASTM D256 |
Heat Deflection Temperature | 102°C @ 0.45 MPa | ASTM D648 |
Nylon 12
Tough Parts With Superior Elongation
Ideal for creating durable end-use parts with high fatigue and chemical resistance. FDM Nylon 12 exhibits up to 300% better elongation and fatigue resistance than other FDM materials along with superior chemical compatibility for the most demanding applications such as repetitive enclosures, snap fits and vibration-resistant parts.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength, Yield | 46 MPa | ASTM D638 |
Tensile Modulus | 1,282 MPa | ASTM D638 |
Elongation at Break | 30% | ASTM D648 |
Unnotched Izod Impact | 200 J/m | ASTM D256 |
Heat Deflection Temperature | 97 °C @ 0.45 MPa | ASTM D648 |
Polycarbonate
High Tensile Strength For Demanding Parts
Polycarbonate provides exceptionally high tensile and flexural strength, making it ideal for manufacturing strong parts, tooling and fixtures. FDM Polycarbonate is a widely used thermoplastic in automotive, aerospace, medical and a variety of other applications for applications where accuracy, durability and stability are critical.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength | 57 MPa | ASTM D638 |
Tensile Modulus | 1,944 MPa | ASTM D638 |
Elongation at Break | 4.8% | ASTM D638 |
Unnotched Izod Impact | 877 J/m | ASTM D256 |
Heat Deflection Temperature | 138°C @ 0.45 MPa | ASTM D648 |
ULTEM 9085
Highest Strength-to-Weight Ratio
ULTEM 9085 by Sabic is a high performance polyetherimide thermoplastic offering excellent strength- to weight ratio and FST (flame, smoke, toxicity) ratings. Ideal for demanding applications, these properties make ULTEM 9085 a great choice for direct manufacturing of fully functional parts, prototypes and tooling with ultra fast lead times.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength | 70 MPa | ASTM D638 |
Tensile Modulus | 2,510 MPa | ASTM D638 |
Elongation at Break | 5.3% | ASTM D638 |
Unnotched Izod Impact | 781 J/m | ASTM D256 |
Heat Deflection Temperature | 153°C @ 0.45 MPa | ASTM D648 |
ULTEM 1010
Highest Tensile Strength, Heat & Chemical Resistance
ULTEM 1010 is a high performance thermoplastic resin used to create fully functional parts ideal for aerospace & automotive manufacturing industries. ULTEM 1010 offers the highest heat resistance, chemical resistance and tensile strength of any additive thermoplastic.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength | 81 MPa | ASTM D638 |
Tensile Modulus | 2,770 MPa | ASTM D638 |
Elongation at Break | 3.3% | ASTM D638 |
Unnotched Izod Impact | 326 J/m | ASTM D256 |
Heat Deflection Temperature | 216 °C @ 0.45 MPa | ASTM D648 |
Materials| Fused Deposition Modeling
ABS
UV Resistant
Flexible
Rigid
Performance
High-Temp
ABS-M30
Strongest Additive ABS Thermoplastic
ABS-M30™ by Stratasys is up to 70 percent stronger than standard ABS, providing significantly better layer bonding, impact resistance and flextural strength than standard level consumer grade ABS. ABS-M30 highly cost effective solution, ideal material for numerous applications including conceptual modeling, functional prototyping, manufacturing tools such as jigs and fixtures as well as end-use production parts.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength, Yield | 32 MPa | ASTM D638 |
Tensile Modulus | 2,230 MPa | ASTM D638 |
Elongation at Break | 4% | ASTM D648 |
Unnotched Izod Impact | 283 J/m | ASTM D256 |
Heat Deflection Temperature | 86°C @ 0.45 MPa | ASTM D648 |
PC-ABS
Strength, Heat Resistance & Flexibility
Polycarbonate-ABS (PC-ABS) combines the desirable strength and heat resistant properties of PC with the flexibility & cost advantages of ABS. PC-ABS is one of the most widely used thermoplastics used in automotive, electronics and variety of other industrial manufacturing applications.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength, Yield | 41 MPa | ASTM D638 |
Tensile Modulus | 1,900 MPa | ASTM D638 |
Elongation at Break | 6% | ASTM D648 |
Unnotched Izod Impact | 481 J/m | ASTM D256 |
Heat Deflection Temperature | 110°C @ 0.45 MPa | ASTM D648 |
ABS ESD7
Static Dissipative
ABS thermoplastic with static dissipative properties (ABS-ESD7) is ideal for applications where a static charge can damage products, impair their performance or cause an explosion. ABS-ESD7 prevents static electricity build up so that it will not produce static shock while also preventing fine powders & dust from sticking. ABS-ESD7 is widely used in electronic manufacturing industries for creating jigs and fixtures, enclosures and packaging.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength | 35 MPa | ASTM D638 |
Tensile Modulus | 2,400 MPa | ASTM D638 |
Elongation at Break | 3.4% | ASTM D638 |
Unnotched Izod Impact | 55 J/m | ASTM D256 |
Heat Deflection Temperature | 96°C @ 0.45 MPa | ASTM D648 |
ASA
UV Stable ABS Thermoplastic
ASA provides the same mechanical properties as ABS-M30 along with enhanced UV stability, making it ideal for outdoor applications. Combined with good impact resistance, toughness and aesthetics, ASA is one of the most broadly used thermoplastics, ideal for concept models, functional production parts such as jigs, fixtures, working prototypes and manufacturing tools.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength | 33 MPa | ASTM D638 |
Tensile Modulus | 2,010 MPa | ASTM D638 |
Elongation at Break | 5.9% | ASTM D638 |
Unnotched Izod Impact | 285 J/m | ASTM D256 |
Heat Deflection Temperature | 102°C @ 0.45 MPa | ASTM D648 |
Nylon 12
Tough Parts With Superior Elongation
Ideal for creating durable end-use parts with high fatigue and chemical resistance. FDM Nylon 12 exhibits up to 300% better elongation and fatigue resistance than other FDM materials along with superior chemical compatibility for the most demanding applications such as repetitive enclosures, snap fits and vibration-resistant parts.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength, Yield | 46 MPa | ASTM D638 |
Tensile Modulus | 1,282 MPa | ASTM D638 |
Elongation at Break | 30% | ASTM D648 |
Unnotched Izod Impact | 200 J/m | ASTM D256 |
Heat Deflection Temperature | 97 °C @ 0.45 MPa | ASTM D648 |
Polycarbonate
High Tensile Strength For Demanding Parts
Polycarbonate provides exceptionally high tensile and flexural strength, making it ideal for manufacturing strong parts, tooling and fixtures. FDM Polycarbonate is a widely used thermoplastic in automotive, aerospace, medical and a variety of other applications for applications where accuracy, durability and stability are critical.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength | 57 MPa | ASTM D638 |
Tensile Modulus | 1,944 MPa | ASTM D638 |
Elongation at Break | 4.8% | ASTM D638 |
Unnotched Izod Impact | 877 J/m | ASTM D256 |
Heat Deflection Temperature | 138°C @ 0.45 MPa | ASTM D648 |
ULTEM 9085
Highest Strength-to-Weight Ratio
ULTEM 9085 by Sabic is a high performance polyetherimide thermoplastic offering excellent strength- to weight ratio and FST (flame, smoke, toxicity) ratings. Ideal for demanding applications, these properties make ULTEM 9085 a great choice for direct manufacturing of fully functional parts, prototypes and tooling with ultra fast lead times.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength | 70 MPa | ASTM D638 |
Tensile Modulus | 2,510 MPa | ASTM D638 |
Elongation at Break | 5.3% | ASTM D638 |
Unnotched Izod Impact | 781 J/m | ASTM D256 |
Heat Deflection Temperature | 153°C @ 0.45 MPa | ASTM D648 |
ULTEM 1010
Highest Tensile Strength, Heat & Chemical Resistance
ULTEM 1010 is a high performance thermoplastic resin used to create fully functional parts ideal for aerospace & automotive manufacturing industries. ULTEM 1010 offers the highest heat resistance, chemical resistance and tensile strength of any additive thermoplastic.
MEASUREMENT | VALUE | STANDARD |
Tensile Strength | 81 MPa | ASTM D638 |
Tensile Modulus | 2,770 MPa | ASTM D638 |
Elongation at Break | 3.3% | ASTM D638 |
Unnotched Izod Impact | 326 J/m | ASTM D256 |
Heat Deflection Temperature | 216 °C @ 0.45 MPa | ASTM D648 |
Material Surface Finishes | Fused Deposition Modeling
Custom Finish
Support structures removed and part is deep colour dyed black
Material Surface Finishes | Fused Deposition Modeling
Standard Finish
Support structures dissolved, some visible layer lines remain.
Custom Finish
Parts finished with a combination of sanding, vapour smoothing and painting.
Start a new FDM Quote
STEP | STP | SLDPRT | STL | DXF | IPT | 3MF | 3DXML | PRT | SAT files
Start a new FDM Quote
STEP | STP | SLDPRT | STL | DXF | IPT | 3MF | 3DXML | PRT | SAT files
Design Guidelines | Fused Deposition Modeling
This design guidelines covers specific design parameters, which will need to be followed to prevent build failures from occurring. We have set the minimums allowed, specified by our engineers which will need to be followed, otherwise your parts may not meet the specific tolerances required or can cause the build to fail. Fused Deposition Modeling (FDM) is an additive manufacturing process by Stratasys that uses continuous filament of thermoplastic polymers.
Accuracy
Parts are built inside of a fully enclosed build chamber which offers significant improvements over desktop FFF 3D Printers. The nature of a fully enclosed build chamber means that shrinkage is precisely controlled to ensure very high part tolerances. The internal temperature of the print chamber is set just below the glass transition temperature of the filament being used. This ensures that warping never occurs during the print process, as well as significantly improves layer adhesion.
Surface Finish
Layers are deposited by molten plastic on a previous layer of cooled plastic with a thickness between 125 - 330 microns with each layer until a solid three-dimensional structure has been built. Depending on the slice height chosen, it can have an impact on the strength of the part. The thinner the slice height, the weaker the part tends to be. Thicker slice heights result in stronger parts, but more noticeable layers.
Pricing
Price is primarily based upon the amount of model & support material required to produce the part. Optimizing your designs for Fused Deposition Modeling will help keep manufacturing costs down. Increasing self supporting angles, reducing wall thickness as well as minimizing steep overhang will help ensure your parts are priced the most competitively in this technology.
Build Size
Our FDM machines have a maximum build volume of: 914 x 609 x 914 mm (36 x 24 x 36 inches). Varied layer resolution of 125 - 330 microns, depending on the settings specified. Standard layer height is 254 microns (0.010″) unless otherwise stated.
Minimum Wall Thickness
1 mm
Minimum Unsupported Wall Thickness
3 mm
Engraved Details
Thickness of 1 mm & depth of 0.3 mm
Embossed Details
Thickness of 1 mm & depth of 0.5 mm
Clearance
0.5 mm
Minimum Hole Size
0.5 mm
Layer Height
125 μm- 330 μm
Maximum Build Size
914 x 610 x 914 mm (36 x 24 x 36 in.)
Tolerances
± .127 mm (± .005 in.) or ± .0015 mm/mm
Surface Finish
Layer lines from the 3D printing process are visible
Support
Support is soluble for most FDM plastics & does not leave defects.
Design Guidelines | Fused Deposition Modeling
This design guidelines covers specific design parameters, which will need to be followed to prevent build failures from occurring. We have set the minimums allowed, specified by our engineers which will need to be followed, otherwise your parts may not meet the specific tolerances required or can cause the build to fail. Fused Deposition Modeling (FDM) is an additive manufacturing process by Stratasys that uses continuous filament of thermoplastic polymers.
Accuracy
Parts are built inside of a fully enclosed build chamber which offers significant improvements over desktop FFF 3D Printers. The nature of a fully enclosed build chamber means that shrinkage is precisely controlled to ensure very high part tolerances. The internal temperature of the print chamber is set just below the glass transition temperature of the filament being used. This ensures that warping never occurs during the print process, as well as significantly improves layer adhesion.
Surface Finish
Layers are deposited by molten plastic on a previous layer of cooled plastic with a thickness between 125 - 330 microns with each layer until a solid three-dimensional structure has been built. Depending on the slice height chosen, it can have an impact on the strength of the part. The thinner the slice height, the weaker the part tends to be. Thicker slice heights result in stronger parts, but more noticeable layers.
Pricing
Price is primarily based upon the amount of model & support material required to produce the part. Optimizing your designs for Fused Deposition Modeling will help keep manufacturing costs down. Increasing self supporting angles, reducing wall thickness as well as minimizing steep overhang will help ensure your parts are priced the most competitively in this technology.
Build Size
Our FDM machines have a maximum build volume of: 914 x 609 x 914 mm (36 x 24 x 36 inches). Varied layer resolution of 125 - 330 microns, depending on the settings specified. Standard layer height is 254 microns (0.010″) unless otherwise stated.
Minimum Wall Thickness
1 mm
Minimum Unsupported Wall Thickness
3 mm
Engraved Details
Thickness of 1 mm & depth of 0.3 mm
Embossed Details
Thickness of 1 mm & depth of 0.5 mm
Clearance
0.5 mm
Minimum Hole Size
0.5 mm
Layer Height
125 μm- 330 μm
Maximum Build Size
914 x 610 x 914 mm (36 x 24 x 36 in.)
Tolerances
± .127 mm (± .005 in.) or ± .0015 mm/mm
Surface Finish
Layer lines from the 3D printing process are visible
Warping & Deformities
Support is soluble for most FDM plastics & does not leave defects.
Industry Advantages| Fused Deposition Modeling
Versatile Materials
Specialized materials for electrostatic dissipation, translucence, biocompatibility, UV Resistance, VO flammability, and FST ratings.
High Accuracy
Parts produced using Stratasys FDM machines are capable of achieving the industries highest tolerances of +/- 0.127 mm.
End-Use Materials
Parts are produced on Stratasys Fortus Series 3D printers offer the industries are ideal for end-use parts offering the industries best layer adhesion and part performance.
Large Build Volumes
Produce parts with build volumes up to 36″ x 24″ x 36″, to produce large, complex parts in a single build.
Industry Advantages| Fused Deposition Modeling
Versatile Materials
Specialized materials for electrostatic dissipation, translucence, biocompatibility, UV Resistance, VO flammability, and FST ratings.
High Accuracy
Parts produced using Stratasys FDM machines are capable of achieving the industries highest tolerances of +/- 0.127 mm.
End-Use Materials
Parts are produced on Stratasys Fortus Series 3D printers offer the industries are ideal for end-use parts offering the industries best layer adhesion and part performance.
Large Build Volumes
Produce parts with build volumes up to 36″ x 24″ x 36″, to produce large, complex parts in a single build.
Aerospace
Automotive
Healthcare
Film & TV
Industrial Design
Architecture
Case Studies | Fused Deposition Modeling
How International Submarine Engineering has been able to replace traditionally machined parts on their newest Explorer class AUVs with 3D printed parts.
How 3D Printing is making architectural models & massing models faster and more affordable than possible with traditional methods.
Fused filament fabrication (FFF) and Fused Deposition Manufacturing (FDM); what is the difference & which one is better?
Case Studies | Selective Laser Sintering
How International Submarine Engineering has been able to replace traditionally machined parts on their newest Explorer class AUVs with 3D printed parts.
How 3D Printing is making architectural models & massing models faster and more affordable than possible with traditional methods.
Fused filament fabrication (FFF) and Fused Deposition Manufacturing (FDM); what is the difference & which one is better?
