CH4 FUSED DEPOSITION MODELLING SYSTEMS

The FDM process was developed in 1988 by S.Crump who founded Stratasys the following year. Since then the company has produced more than 1000 systems. The first product ,the 3D MODELER, was introduced by the company in 1922. The FDM process works by extruding a thermoplastic material and depositing it layer-by-layer fusing it to the layer beneath it, to form a 3D model. FDM creates functional prototypes using a variety of engineering materials like ABS, and polycarbonate.

PROCESS
Step 1 : The Preparation FDM begins with a 3D CAD file that is oriented in the appropriate orientation for building the part. The data is then mathematically sliced into 2D cross-sections (layers) along the Zaxis. Step 2 : The Build The nozzle is heated to melt the plastic filament and is mounted to a mechanical stage which can be moved in both horizontal and vertical directions. As the nozzle is moved over the table in the required geometry, it deposits a thin bead of extruded plastic to form each layer and create a two-dimensional cross section of the model.

PROCESS
The plastic hardens immediately after being squirted from the nozzle and bonds to the layer below. The platform then descends where the next layer is extruded upon the previous. This continues until the model is completed. The entire system is contained within a chamber which is held at a temperature just below the melting point of the plastic. Step 3 : The Completion Once all the layers are drawn and the model is complete, the model is then removed from the platform, and the support structures are removed from the part.

PROCESS PARAMETERS
FDM 2000 FDM 3000 FDM 8000 Quantum

Build size mm
Accuracy mm Size mm

254 x 254 x 254 254 x 254 x 406 457 x 457 x 609

600 x 500 x 600

+/- 0.127

+/- 0.127

+/- 0.127-0.254 +/- 0.127

660x 914 x 1067

660 x 1067 x 914

1486 x 1905 x 1003

2235 x 1981 x 1118

PROCESS PARAMETERS
Weight Kg Power requirements 160 220-240 VAC 50/60 Hz 10A single phase 160 208-240 VAC 50/60 Hz 10A single phase 392 220-240 VAC 50/60 Hz 10A single phase 1134 208-240 VAC 50/60 Hz 10A single phase

Materials

ABS (white) Investment casting wax Elastomer 0.254 to 2.54 mm

0.05 to 0.762 mm

ABS (white) Investment casting wax Elastomer 0.254 to 2.54 mm

0.05 to 0.762 mm

ABS

ABS

Layer width
Layer thickness

0.254 to 2.54 mm
0.05 to 0.762 mm

0.38 to 0.51
0.18 to 0.25 mm

ADVANTAGES

True desktop manufacturing system that can be run in office environment. There is no worry of exposure to toxic fume and chemicals. The process is clean, simple, easy to operate and produces no waste Fast building for bottle like structure or hollow parts Material is supplied in spool form which is easy to handle and can be changed in minute Materials used are very cost effective, typical parts cost under US$20 A good variety of material is available including colour ABS and Medical ABS, investment casting wax and elastomer Mid range performance/cost RP system and is the best selling RP system in 1995

DISADVANTAGES

Accuracy is relatively low and is difficult to build parts with complicated details Poor strength in vertical direction Slow for building a mass part

APPLICATIONS

It does not need laser systems, uses relatively inexpensive binders, and is easy to change materials. The main difficulties are in controlling temperature within the growing part, the need to provide support structures for the growing model The accuracy which is limited to the nozzle diameter.

APPLICATIONS

Limited number of prototypes needed (1-10) Concept Models Functional testing Si3N4 components with good mechanical properties and microstructure were produced with a filament containing 55 vol % of the ceramic. After FDM, green parts were densified by hot pressing and gave four point bend strengths similar to that of hot isostatic pressed parts. A fine scaled piezoelectric composite structure can be made consisting of PZT and polymer. The piezoelectric properties of the composite are similar or superior to conventionally processed PZT composites. Composites with controlled composition distribution and a variety of microstructures can be made by combining filaments of different compositions.

Rapid Manufacturing at BMW

Rapid Manufacturing Jigs and Fixtures with FDM Rapid prototyping has become a standard practice in product development. At the BMW AG plant in Regensburg, Germany, FDM (fused deposition modeling) continues to be an important component in vehicle design prototyping. But moving beyond prototyping, BMW is extending the application of FDM to other areas and functions, including rapid manufacturing. BMW has determined that the FDM process can be an alternative to the conventional metal-cutting manufacturing methods like milling, turning, and boring.

Landing Gear Prepared for Flight