

Fused Deposition Modeling
(FDM) 3D Printing Services
High Performance Thermoplastics
Industrial Fused Deposition Modeling (FDM) by Stratasys produce 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 industries best repeatability, accuracy and mechanical performance.


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.


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-M30
Strongest Additive ABS PlasticABS-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 & FlexibilityPolycarbonate-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 DissipativeABS 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 ThermoplasticASA 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 ElongationIdeal 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 PartsPolycarbonate 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 PlasticULTEM 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 ResistanceULTEM 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


Standard
Basic FinishSoluble 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 |


Vapour Smoothed
Standard FinishVapour 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 |


Performance Paint
Premium FinishPainting 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.
Design Guidelines


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.


Tolerances
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
125 - 330 Microns

Surface Finish
Uniform, MatteApplications & Case Studies


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.


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


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