Fused deposition Modelling or Fused Filament Fabrication is the easiest among the 3D
printing processes, you can use this technology for making school - college projects, Interior Design scale models, wall patterns, figurines and many more products. In this article we will discuss the steps involved in the FDM printing process.
1. Make a 3D model
This is one of the crucial steps involved in 3D printing, making 3D Computer Aided Design (CAD) models using various CAD software. Commonly used software in mechanical design are Solidworks, Siemens NX, PTC Creo and many more. Architecture and Interior designers use Autodesk 3ds Max to make floor plans. Free-form designs can be made in software like Zbrush, Blender, Autodesk Maya etc. The design needs to be considered for additive manufacturing processes. Support structures to be avoided wherever possible. Overhangs and features like chamfers to be used to eliminate supports. The part can be printed in pieces and assembled together later. In many cases assemblies can also be printed as print-in-place parts.
2. Convert to STL
All mechanical design software support conversion of solid part files to Standard Triangle Language or Standard Tessellation Language (STL) file format. Here the solid file is converted into triangles. Resolution of these triangles plays an important role in
conversion of curved surfaces. It is observed that curves are converted to facets of
polygons, in such cases resolution of the triangles needs to be increased. Smaller and
denser tessellations give better curved and circular features as seen in a print.
3. Slice in Slicing Software
Once the file is converted to STL format, it can be imported to a slicing software. Open-
source software, like Ultimaker Cura, Prusa Slicer are commonly used. Secondly, machine manufacturers provide proprietary software for their machines which contain the optimum parameters for printing. In many cases, machine manufacturers provide
configuration files for their printers which can be used in open source software.
Commonly available proprietary software are Creality Print, Prusa Slicer, Bambu Studio,
Preform, Lychee Slicer etc. The slicer software estimates duration of the print and weight (in grams) and length of filament required for the part to be printed.
4. Print on FDM 3D printer
The choice of slicer software you use plays an important role in the final print that you
will get, certain parameters like infill, layer height, type of support structure determines
strength and finish of your printed part. The slicing software exports the G-code
(Geometric Code) file which is transferred to the printer via a SD card or a pen drive.
Currently printers also support Wi-Fi and LAN printing. This gcode file is read by the
printer and the printer starts printing.
5. Post Processing
After the print is completed, the print is removed from the bed with the help of a metal
scraper; in case of glass bed printers or by lifting the printer bed slightly so the print
comes off easily in case of spring steel beds. Polyethyleneimine (PEI) coated glass printer bed and PEI coated spring steel printer bed give good adhesion while printing and easy part removal after printing is completed. Common post processing includes support removal by breaking supports with hand or using nipper pliers to remove support from intricate parts. Secondly, parts can be sanded with sandpaper for better finish. Primer is sprayed for colouring the printed part if required.
In conclusion, Fused Deposition Modeling (FDM) is an accessible and versatile 3D printing method suitable for a wide range of applications from educational projects to intricate models and functional prototypes. Its straightforward process, from 3D modeling to slicing and post-processing, empowers users to create detailed and customized objects efficiently, leveraging modern software tools and innovative printing techniques.
To watch our video on Fused Deposition Modeling (FDM) Printing, click here
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