How FFF and FDM Work

Fused filament fabrication (FFF), also called fused deposition modeling (FDM), builds a part one layer at a time. Plastic filament feeds into a heated nozzle, the nozzle traces the shape of each layer, and the layers bond as they cool.

There is no mold and no tooling cost, so the first part costs about the same as the tenth. It is the fastest way to get a strong plastic part in your hands, and it gives you the widest material choice of any printing method we offer.

What FFF and FDM Are Good For

• Large parts. Our build envelope reaches 36 x 24 x 36 inches, so most parts print in one piece instead of being split and bonded.
• Functional prototypes. Test fit, strength, and heat resistance in the same material you plan to produce in.
• Low-volume production. Run 1 to 500 parts without paying for a mold.
• Shop floor tooling. Jigs, fixtures, drill guides, and assembly aids that would be slow and expensive to machine.
• Demanding industries. Aerospace, medical, industrial, and high-tech work where material traceability and repeatability matter.

Materials

High-temperature and flame-retardant

• Ultem 9085 (natural and black)
• Ultem 1010
• PEEK, PEEK CF10, PEEK CF20
• PEKK, PEKK (Vega)
• ABS-FR, PC-FR, Onyx FR

Engineering grades

• Polycarbonate (PC)
• PC-ABS
• PC-ISO (medical grade)
• Nylon 12 CF
• Onyx (Nylon 6 CF) and Onyx ESD
• ABS M30 and ABS-ESD7
• ASA (white and black)
• PETG, PCTG, PLA
• TPU 95A

Continuous fiber reinforcement

Fiber can be laid inside the part as it prints, which adds strength where the part needs it most.

• Carbon fiber
• Kevlar
• Fiberglass
• HSHT fiberglass

Not sure which grade fits your part? Tell us what the part has to survive, and we will recommend one.

Tolerances

• X/Y: 0.005 in, or 0.002 in/in, whichever is greater
• Z: the X/Y tolerance plus one layer height

Maximum Part Size

914 x 610 x 914 mm (36 x 24 x 36 in)

Lead Times

• Fastest: next business day
• Standard: 3 to 4 business days

Finishing Options

• Spray paint
• Cerakote
• Vapor smoothing for a sealed, glossier surface
• Bonding for parts larger than the build envelope
• Drilling and reaming
• Threaded inserts and captured hardware (we review the design first)