Fused Deposition Modeling (FDM) remains the most affordable 3D printing technology in the market today. It is particularly suited to rapid high-volume prototypes with reduced tooling costs and is optimal for use in many applications. FDM is also pretty good at creating functional parts such as enclosures.

However, like every manufacturing process, FDM comprises certain disadvantages and unique conditions for usage. This article will take you through how and when to make tweaks to get the best results for FDM printing designs.

What is the FDM Printing Process?

Fused Deposition Modeling (FDM) is an additive manufacturing technique. A heated nozzle extrudes molten filament onto a build platform. The material becomes rigid and hardens instantly as it cools, adhering to the prior layer.

The printer follows a digital model, creating precise structures. FDM printers use thermoplastic materials like PLA, ABS, or PETG. The process is relatively simple and affordable, making it ideal for rapid prototyping and small-scale production.

FDM works by gradually adding layers until the full object is completed. The environmental coating then adheres to the layer below and forms a rigid hard surface in the end product. The process provides the opportunity to create impressive designs with fewer restrictions.

How Do You Design for FDM Printing?

Designing entails the designer knowing some of the characteristics of FDM printing. Here are the key factors to consider:

1. Consider Print Orientation

Selecting the proper orientation affects strength and surface finish that cannot be overemphasized. It defines the mode of cohesion between the layers and the appearance of the final product. You should attempt to align your model in such a manner that it has the barest of support structures while it has the optimum structural strength.

2. Consider Overhangs & Supports

FDM printers have difficulties in having high overhangs. Angles measured to be more than 45° are always forced to have to use additional supports. Avoid the excessive application of overhangs or designing the support into a model to avoid post-processing time.

3. Wall Thickness and Density

It is recommended you make your model thick enough on the walls. These walls can barely be printed, or they may possess inadequate strength. A good rule of thumb is to use at least 2-3 perimeters for durability and proper extrusion.

4. Incorporate Proper Layer Heights

Layer height influences the time that a model will take to be printed as well as the resolution to be achieved. Higher layers create smooth surface textures but they always take longer time to print.

5. Avoid Thin Features and Small Gaps

FDM printing is not ideal for slim or well-detailed sections. Small gaps, tiny details, and delicate parts may not be printable, or at least not easy to print. So, increase the thickness to make a particular underpart thinner in a bid to make it print successfully.

6. Use Fillet and Rounded Edges

Embed your models with fillets, and rounded edges so that the quality and print strength are regarded. This also improves printability and reduces potential failure during the process.

7. Ensure Proper Clearances

When designing moving parts provide adequate space between, known commonly as clearance. FDM printers are not efficient for tight tolerances, so leave room for ease of movement.

8. Design for Post-Processing

FDM prints often require post processes like sanding or removing support material. Make post-processing tools easily accessible through a simple interface.

9. Test with Smaller Prototypes

It’s recommended to print large elaborate structures initially using small samples. This allows you to catch any issue at the early stage and also check your design originally for the best result in print.

Tips for Advanced FDM Design

FDM printing involves several strategies to optimize prints. These methods reduce costs, improve quality, and simplify the process.

Splitting Your Model

Splitting the model can reduce the complexity level of models. It displaces the large support structures as part of the employment process. Due to the complexity of the shapes, large shapes are subdivided into several smaller ones for printing ease. These sections originate in separate sheets and are collated together. The intended approach saves time and material, making the process more efficient.

Hole Orientation

Proper hole orientation minimizes support. Horizontal-axis holes usually require supports, which can be avoided by rotating the part 90°. Start with blind holes followed by small ones and then residual large holes. Changing the hole direction in the material leads to a decrease in the amount of material used and minimizes the time to complete a print.

Build Direction

Build direction affects print strength. FDM prints are weaker along the layer lines due to how material bonds. If layers are poorly aligned then bending, and stress on a part can lead to cracks. The change in the part orientation to position the layers along the direction of stress improves the strength of the part. Correct positioning makes the loads to be distributed more evenly.

FDM Materials

FDM printing offers a variety of materials, each with distinct properties. Here’s a summary of the most commonly used materials:

FDM 3D Printing: Best Practices

To achieve the best results with FDM 3D printing, consider the following best practices:

• Bridge Length: If a bridge goes beyond 5mm, it develops a low profile, and is marked by support material. To avoid this, it can be solved either by dividing the design into smaller elements or using post-processing for the problem.
• Vertical Holes: For a more accurate vertical hole diameter, it’s advisable to drill the holes after the prints are made. This makes it accurate compared to when one directly prints the holes in the material.
• Support Structures: Adding supports enables you to print walls with angles of more than 45°. It allows richer geometries without any compromise in the quality of production.
• Chamfer or Radius on Edges: To improve print quality and reduce the challenge of peeling, lift the part edges that rest on the build plate 45 degrees or create a radius on all sides. 
• Small Vertical Pins: If the design uses small vertical pins they must be reinforced with a fillet at the pin base. However, for even greater precision, you can put an off-the-shelf pin in the printed hole.
• Model Optimization: Changing the model splitting, adjusting the hole positioning, and selecting the right build direction will help you save money, and time, and provide parts with high strength and quality.

Conclusion

FDM 3D printing is an affordable additive manufacturing process. Appropriate choice of material and design ensures the best print quality and mechanical durability. Reducing print issues is achieved by changing model orientation and adding supports. Thus, it is more effective to pay close attention to managing overhangs and holes accurately.

So if you have a project that requires accurate and dependable FDM 3D parts to be printed with FDM materials. Hailing from our years of experience and focus on excellent service delivery, our business avails specialized solutions, unique to your particular project needs. Whether in prototyping or printing large volumes of products, we ensure our customers get only the best quality of prints in the minimal time possible. Please feel free to call or email us for any FDM 3D printing services.