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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

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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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.

FDM Fortus 450 3D printer
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What is Fused Deposition Modeling (FDM)?

FDM Fortus 450 3D printer

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

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ABS

ASA 3D Printing

UV Resistant

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Flexible

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Rigid

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Performance

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High Temperature

ABS FDM 3D Printed Part

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

Material Data Sheet
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 Data Sheet
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 Data Sheet
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 Data Sheet
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 Data Sheet
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 Data Sheet
ULTEM 9085 3D Printed Part

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

Material Data Sheet
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 Data Sheet

Materials| Fused Deposition Modeling

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ABS

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UV Resistant

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Flexible

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Rigid

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Performance

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High-Temp

ABS FDM 3D Print

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

Material Data Sheet
PC-ABS 3D print

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 Data Sheet
ABS ESD7 3D Print

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 Data Sheet
ASA 3D Printing

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 Data Sheet
Nylon FDM 3D Printing

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 Data Sheet
Polycarbonate 3D Print

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 Data Sheet
ULTEM 9085 3D Print

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

Material Data Sheet
ULTEM 1010 3D Print

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 Data Sheet

Material Surface Finishes | Fused Deposition Modeling

Support structures dissolved, some visible layer lines remain

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.

 

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Start a new FDM Quote

STEP | STP | SLDPRT | STL | DXF | IPT | 3MF | 3DXML | PRT | SAT files

Get an Instant Quote
 
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.

Download Full Design Guidelines
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.

Download Full Design Guidelines
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.

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Aerospace

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Automotive

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Healthcare

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Film & TV

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Industrial Design

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Architecture

Case Studies | Fused Deposition Modeling

Submarine 3D Printed parts

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

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

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

Read Case Study ->

Case Studies | Selective Laser Sintering

Submarine 3D Printed parts

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

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

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

Read Case Study ->