Extrusion

(FDM, FFF)

Seeking the best in FDM Printing or FFF Printing?  Then our Extrusion 3D Printing service is for you.  Capable of quickly delivering parts made with true engineering plastics, our Extrusion printers reliably deliver high quality models, tools, fixtures, and production parts.  In addition to durable parts, we are also capable of delivering large FDM prints, with expertise delivering parts much larger than the typical cubic yard build envelope.  Have a project in mind?  Submit an RFQ through our secure portal or email us with more information and we'll be in touch.

 

Don't care to learn about all the specifics...just need some great extrusion 3D printed parts?  

Submit an RFQ via our secure platform and let our experts do the thinking for you, presenting the right solutions for the application. Or email us with a description of your project and we'll be in touch.

 

Process Overview

Extrusion techniques will extrude material from a precisely controlled print head to form each layer of the model. After a layer is completed, the print head will rise or the build tray will descend one layer thickness so that the print head can extrude the next layer. This creates visible stepping. Considering there is no supporting powder or surrounding media, extrusion prints will always require support structures for stalactites and overhangs with a large minimum overhang. Despite the support structures, extrusion processes are typically fast and affordable.

Branded Processes (Also Known As)

  • Fused Deposition Modeling (FDM)
  • Fused Filament Fabrication (FFF)

Process At A Glance

Common Materials

ABS, Nylon 12, Ultem 9085, PC, PC-ABS

Standard Tolerance

+/-.005" for the first inch, +/- .002" each additional inch (.127mm +/- .50mm/25mm)

Stock Surface Finish

~80 µin Ra

Lead Time

1-5 Business Days

Maximum Size

10' x 12' x 25' (3000mm x 3600mm x 7500mm)

Minimum Layer Thickness

0.005" (0.125mm)

Minimum Feature Size

0.005" (0.125mm)

Minimum Wall Thickness

0.04" (1mm)

While FDM is generally known for having a rough, stairstepped surface finish, some materials can be processed at .007" or .005" layers, which provides a more aesthetically appealing finish
While FDM is generally known for having a rough, stairstepped surface finish, some materials can be processed at .007" or .005" layers, which provides a more aesthetically appealing finish

Advantages

  • Material Selection - Choose from over 15 materials with a wide range of properties
  • Relatively Affordable - Thermoplastic filaments are relatively inexpensive, making extrusion a cost effective option, especially for larger prints
  • Short Lead Times - Extrusion parts will typically ship in 1-5 business days
  • Large Build Volume - Our largest printer can handle prints 10' x 12' x 20'.  Those measurements are in feet!

Limitations

  • Low durability - To successfully be jetted from an ink head, fairly low viscosity - and thus typically less durable - materials are also required.  Further, as a general rule, photopolymers weaken over time, especially when exposed to light.  
  • Downward facing surfaces - Support structures required, the removal of which can impact surface finish and post-processing speed
FDM, FFF, many FDM options
3Diligent offers a tremendous range of extrusion printing materials, from basic ABS to aerospace-grade thermoplastics like Ultem 9085

Example Machines

  • Cincinnati BAAM Alpha
  • Cosine AM1
  • Markforged MarkX
  • Markforged Mark One
  • Markforged Mark Two
  • Stratasys Dimension 1200es
  • Stratasys Dimension SST
  • Stratasys Fortus 250mc
  • Stratasys Fortus 380mc
  • Stratasys Fortus 400mc
  • Stratasys Fortus 450mc
  • Stratasys Fortus 900mc
  • Stratasys Titan
  • Stratasys uPrint SE Plus
  • Stratasys Dimension
FDM Printer, FDM Printing, Extrusion Printing
Fortus 900mc. Photo Credit: Stratasys

Example Materials

  • ABS Plastic
  • ABS-M30
  • ABS 40% Glass Fiber
  • Carbon Fiber ABS
  • Carbon Fiber
  • Fiberglass
  • Kevlar
  • Nylon 12
  • Polyproypylene (PP)
  •  Onyx
  • Polycarbonate (PC)
  • PC-ABS
  • PPSF/PPSU
  • PC-ISO
  • Ultem 1010
  • Ultem 9085

 

FFF Printers don't have the same pedigree as Stratasys FDM printers, but some machine operators can deliver excellent parts at great prices using FFF
FFF Printers don't have the same pedigree as Stratasys FDM printers, but some machine operators can deliver excellent parts at great prices using FFF