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Manufacturing with FDM 3D printing
FDM (Fused Deposition Modeling) 3D printing is a versatile technology that builds custom parts by heating and extruding thermoplastic materials layer by layer.
This method is not only suitable for initial and functional prototyping but also excels in low-volume production across a range of robust plastics.
Despite being the most cost-effective 3D printing technology available, FDM offers substantial benefits beyond just small-scale manufacturing. When you choose FDM printing, you gain access to a wide array of thermoplastics, including PLA, ABS, TPU, PETG, and PEI.
This technology ensures precise dimensional accuracy of ±0.5% with a minimum tolerance of ±0.5 mm (0.0196 inches), making it ideal for applications that demand high accuracy and material versatility.
Whether you are in the prototype phase or ready for production, FDM 3D printing provides an efficient and economical solution for creating high-quality parts tailored to your specifications.
Fused Deposition Modeling (FDM) 3D Printing
Fused Deposition Modelling (FDM) is a widely used 3D printing process that efficiently creates prototypes and functional production parts, typically within a very short time frame. This technique utilises a variety of thermoplastic materials to produce durable final products, tailored to meet specific engineering and design requirements.
How It Works: In FDM, thermoplastic filaments are heated and extruded through a nozzle, then deposited layer by layer to build the part.
Filament Loading: The process starts by loading a spool of thermoplastic filament into the printer.
Heated Extrusion: The filament is heated to a molten state and extruded through a precision nozzle.
Layer Formation: The nozzle moves over the build platform, depositing the material according to the digital design. Each layer hardens immediately after extrusion as the material cools.
Layer Addition: After one layer is complete, the build platform lowers slightly to allow the next layer to be added on top. This process repeats until the part is fully formed.
Post-Processing: Once printing is complete, minimal post-processing is required. The support structures (if used) are removed, and the surface can be finished or smoothed if necessary.
Benefits of FDM: Speed: FDM can rapidly produce parts, making it ideal for prototyping and short production runs.
Material Diversity: Supports a wide range of thermoplastics, including ABS, PLA, PETG, and specialised materials like conductive, flexible, or composite filaments.
Durability and Functionality: Parts produced by FDM are mechanically robust, making them suitable for both prototype testing and functional use.
Cost-Effectiveness: FDM is one of the most economical 3D printing technologies, perfect for budget-conscious projects without compromising quality.
FDM technology is particularly beneficial for designers, engineers, and manufacturers who need fast turnaround times and functional parts without the high costs associated with traditional manufacturing. Whether it's for rapid prototyping or end-use production, FDM provides a reliable and affordable solution.
FDM in Industrial Applications
Our clients often choose FDM for its practicality and the significant cost savings it offers, especially when dealing with complex parts or customisations. The technology's flexibility in terms of scale and materials makes it an excellent choice for a diverse array of industries requiring precise, reliable, and rapid production capabilities.
FDM 3D Printing capabilities in South Africa
| Maximum build size | Standard lead time | Dimensional accuracy | Layer thickness | Infill |
|---|---|---|---|---|
| Up to 1200 x 600 x 600mm | 3 working days | ± 0.5% with a lower limit on ± 0.5 mm (0.0196 in) | 100-300 μm | 20-80% |
FDM materials in South Africa
Prototyping FDM materialsIdeal for fast and affordable rapid prototyping and modelling.
ABS (Acrylonitrile Butadiene Styrene)
PLA (Polylactic Acid)
Nylon
ASA (Acrylonitrile Styrene Acrylate)
PETG (Polyethylene Terephthalate Glycol)
HIPS (High Impact Polystyrene)
PC (Polycarbonate)
Polypropylene
PVA (Polyvinyl Alcohol)
TPU (Thermoplastic Polyurethane)
Carbon Fiber
Acrylonitrile
Metals
PET (Polyethylene Terephthalate)
Flex Filament
Nylon 12
PEEK (Polyether Ether Ketone)
Thermoplastic Polyurethane
Wood Filament
Electrically Conductive PLA
South African Manufacturing Standards for FDM 3D Printed Parts
We manufacture your custom parts according to strict South African manufacturing standards, ensuring that all parts and processes adhere to the the highest standards.
Each order comes with a comprehensive inspection report verifying that these standards have been met.
After printing, parts undergo finishing touches to ensure that your parts not only meet but exceed your expectations in terms of quality and aesthetics.
Design guidelines for FDM printing in South Africa
The table below summarises the recommended and technically feasible values for the most common features encountered in FDM 3D printed parts.
| Feature | Recommended size |
|---|---|
| Unsupported walls | 0.8 mm (0.0315 in) |
| Supported walls | 0.8 mm (0.031 in) |
| Minimum feature size | 2.0 mm (0.0787 in) |
| Minimum hole size | 2.0 mm (0.0787 in) |
Advantages and drawbacks of FDM 3D printing
Advantages
- FDM is the most cost-effective way to produce custom thermoplastic parts and prototypes.
- Lead times are short (typically a few days).
- A wide range of materials is available, suitable for prototyping and industrial applications.
Drawbacks
- FDM is not suitable for parts with very small details due to its low resolution.
- Parts are likely to have visible layer lines, so post-processing is required for a smooth finish.
- The layer adhesion mechanism makes parts inherently anisotropic.
How FDM stacks up against other 3D printing technologies in South Africa
| Table header 0 | Materials | Price | Dimensional accuracy | Strengths | Build volume | Layer thickness | Min. feature size |
|---|---|---|---|---|---|---|---|
| FDM | 5 | R | ± 0.5% with a lower limit on ± 0.5 mm | Low cost, wide range of materials | 500 x 500 x 500 mm (19.68" x 19.68" x 19.68") | 100-300μm | 2.0 mm (0.0787’') |
| Industrial FDM | 6 | RRRR | ± 0.3% with a lower limit of ± 0.3 mm (± 0.012") | High level of repeatability, engineering grade materials | 406 x 355 x 406 mm (15.98” x 13.97” x 15.98") | 100-330μm | 2.0 mm (0.0787’') |
| Prototyping SLA | 8 | RR | ± 0.3% with a lower limit of ± 0.3 mm (± 0.012") | Smooth surface finish, fine feature details | 145 × 145 × 175 mm (5.7" x 5.7" x 6.8") | 50-100μm | 0.2 mm (0.00787’') |
| Industrial SLA | 3 | RRR | ± 0.2% with a lower limit of ± 0.13 mm (± 0.005") | Smooth surface finish, fine feature details, big print area | 500 x 500 x 500 mm (19.68" x 19.68" x 19.68") | 50-100μm | 0.2 mm (0.00787’') |
| SLS | 4 | RR | ± 0.3% with a lower limit of ± 0.3 mm (± 0.012”) | Design flexibility, supports not required | 395 x 500 x 395 mm (15.53" x 19.68" x 15.53") | 100μm | 0.5 mm (0.0196”) |
| MJF | 2 | RRR | ± 0.3% with a lower limit on ± 0.3 mm (0.012’') | Design flexibility, supports not required | 380 x 285 x 380 mm (14.9’’ x 11.2’’ x 14.9’') | 80μm | 0.5 mm (0.0196”) |
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Our History
One of the world's top universities, Universalis was founded on the ideal of interactive learning.
Our Faculties
We offer more than 40 undergraduate courses at Universalis for a wide range of subjects.
Our Faculties
We offer more than 40 undergraduae courses at Universalis for a wide range of subjects.