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Fused Deposition Modeling
(FDM) 3D Printing Services

High Performance Thermoplastics

Industrial Fused Deposition Modeling (FDM) by Stratasys produces robust, functional parts with remarkable dimensional stability and accuracy.  Manufacture end-use parts in sizes up to 36 x 24 x 36 inches in a single print with the industry's best repeatability, accuracy and mechanical performance.

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FDM 3D Printed sample cube

What is Fused Deposition Modeling?

Fused Deposition Modeling (FDM) 3D printing provides an extensive selection of advanced thermoplastics that are on par with those used in traditional manufacturing processes. This makes it an excellent choice for producing end-use parts, conducting real-world material property tests, or creating durable jigs, fixtures, and templates for production purposes. With 14 distinct 3D printed materials available, Forge Labs' FDM (Fused Deposition Modeling) technology offers remarkable versatility, making it well-suited for a range of specialized applications. These applications include medical devices, electric static dissipative parts, or high-temperature scenarios where Flame, Smoke Toxicity (FST) ratings are of utmost importance.

 

Forge Labs utilizes Stratasys Fortus series 3D printers, known for their exceptional accuracy, part repeatability, and one of the largest commercially available printing envelopes in the market. With these machines, you can manufacture large and intricate designs using a wide range of thermoplastics, all in a single build. The maximum build volume of 36 x 24 x 36 inches ensures that even complex projects can be accommodated. The strength and precision delivered by Stratasys FDM machines set them apart as the preferred choice for achieving remarkable results.

FDM Fortus 450 3D printer

36" x 24" 

Max X/Y Build Volume

± 0.2

MM Part Tolerances

14

High Performance Materials

2-5 Day

Average Lead Time

Materials | Fused Deposition Modeling

ABS 3D printing icon

ABS

ASA 3D Printing icon

UV Resistant

nylon12 icon

Flexible

polycarbonate icon

Rigid

ultem 9085 icon

Performance

ultem 1010 icon

High Temperature

ABS FDM 3D Printed Part

ABS-M30

Strongest Additive ABS Plastic

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

Material Datasheet
PC-ABS 3D Printed jig

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

Material Datasheet
ESD7 3D Printed Part

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

Material Datasheet
ASA 3D Printed Part

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

Material Datasheet
Nylon 12 3D Printed Part

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

Material Datasheet
Polycarbonate 3D Printed Part

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

Material Datasheet
ULTEM 9085 3D Printed Part

ULTEM 9085

Highest Strength-to-Weight Ratio Plastic

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

Material Datasheet
ULTEM 1010 3D Printed Part

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 Datasheet
Fused Deposition Modeling

Material Surface Finishes

FDM part surface finish

Standard

Basic Finish

Soluble supports are dissolved in an ultrasonic cleaning tanking. Physical supports on high temperature materials are removed by hand (if required).

 

Surface Texture

Visible Layers.

Color & Appearance

Black, White, Green, Red, Blue, Orange, Yellow

Detail

Details vary depending on axis

Porosity

Tiny spaces exist between layers.

Turnaround Time

No additional time required
FDM surface finish vapor smoothed

Vapour Smoothed

Standard Finish

Vapour smoothing is a cost effective solution that improves the cosmetics of FDM 3D printed parts. This finish seals the part and helps provide a uniform finish

 

Surface Texture

Smooth & Uniform.

Color & Appearance

Black, White, Green, Red, Blue, Orange, Yellow

Detail

Intricate details can be lost during the smoothing process.

Porosity

None.

Turnaround Time

+1 business day
FDM painting services

Performance Paint

Premium Finish

Painting enables a highly durable automotive-grade coating of 3D printed parts. Parts are hand finished to a high quality and painted using high quality coating equipment.

 

Surface Texture

Matte to semi-gloss

Color & Appearance

Color matching available

Detail

Fine details may be lost if polishing is required.

Porosity

None

Turnaround Time

+2 or more business days

Why Use FDM 3D Printing?

FDM allows for a wide range of materials to be used, including different types of thermoplastics. This versatility allows for a range of materials with specific properties such as strength, flexibility, or heat resistance, depending on the intended application.  The enclosed build chamber of FDM  minimizes temperature variations and drafts, reducing the chances of warping, curling, or other dimensional inaccuracies in the printed object. It improves the overall print quality and accuracy of the final part allowing parts printed on Stratasys machines to achieve the industries highest 3D printing tolerances.

FDM offers a wide selection of thermoplastics that can be used for printing, including materials with specialized properties like high temperature resistance, flame retardancy, or electrical conductivity. This versatility allows engineers and designers to choose the most suitable material for their specific application requirements, enabling the production of parts tailored to meet specific needs.

FDM Nylon Part Submarine 3D Printed
Fused Deposition Modeling

Design Guidelines

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.
build volume icon

Maximum Build Volume

914 x 609 x 914 mm (36 x 24 x 36 inches)

We print using large-scale industrial 3D printers manufactured by Stratasys. The build volume of our largest FDM printer is 914 x 610 x 914 mm (36 x 24 x 36 in). The printer is capable of using a range of materials, including engineering-grade thermoplastics, and is often used in aerospace, automotive, and medical industries for rapid prototyping and end-use part production.

accuracy icon

Tolerances

±0.2%, with a lower limit of ±0.2 mm

Parts are built inside of a fully enclosed build chamber to precisely control part accuracy. 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.

layer height icon

Layer Height

125 - 330 Microns
The layer height is the overall Z resolution of the part; we avoid stepping artifacts on important features of your models by orienting the part(s) along the Z plane or at a 20 degree angle on all sides. Unless otherwise specified, all SLS parts are printed at a 100 micron layer height.
surface finish icon

Surface Finish

Uniform, Matte
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.
The cost of FDM parts 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.
Fused Deposition Modeling

Applications & Case Studies

Submarine 3D Printed parts

Replacing Machined Parts with 3D Printing

How International Submarine Engineering has been able to replace traditionally machined parts on their newest Explorer class AUVs with 3D printed parts.

Read Case Study
3D printed architectural model

Massing Models with FDM

How 3D Printing is making architectural models & massing models faster and more affordable than possible with traditional methods.

Read Case Study
Fortus 450 Print head

FFF vs FDM

Fused filament fabrication (FFF) and Fused Deposition Manufacturing (FDM); what is the difference & which one is better?

Read Case Study
aerospace

Aerospace

automotive

Automotive

healthcare

Healthcare

film & tv

Film & TV

design

Design

architecture

Architecture

Frequently Asked Questions