Learning Module

Product Design and Development

Laboratory

FDM
“Fused Deposition Modeling Module”
 Product Design and Development
Fused Deposition Modelling

Additive Manufacturing
Additive manufacturing (AM) is defined as the technique of integrating materials to
form a three-dimensional (3-D) object by the American Society for Testing and
Materials. AM has become a manufacturing technique that offers practicality and
faster processing compared to other manufacturing techniques, helping industries to
accelerate product launches to the market.

Based on International Standard Organization (ISO) and American Society for Testing
and Materials (ASTM) standards, AM methods are classified into seven categories as
follows:

Sheet lamination (SL)

Material extrusion (ME)

Powder bed fusion (PBF)

Direct energy deposition (DED)

Binder jetting (BJ)

Material jetting (MJ)

Vat photopolymerization (VP)

1
 Product Design and Development
Fused Deposition Modelling

3D printing is an AM technology that produces parts by forming layer by layer based

on digital design data using CAD (Computer Aided Design) or CAM (Computer Aided
Manufacturing). Some software that can be used to generate 3D design models are
AutoCAD, Inventor, Solidworks, and CATIA. The materials used in the 3d printing
process can be either solid (sheet, filament, and powder) or liquid. The processing
methods of each type of material also vary, such as joining, melting, binding and
others. One of the most commonly used 3d printing methods is FDM which belongs
to the material extrusion (ME) category.

Fused Deposition Modelling

Fused deposition modeling (FDM) is the most popular Material Extrusion-based AM
method that utilizes thermoplastic polymer-based material (filament). FDM operates
by extruding thermoplastic material through a nozzle at melting temperature. The
nozzle then prints layer by layer to form a three-dimensional object.

In FDM, the filament is connected to an extruder and nozzle. The nozzle head can
move in the X and Y-axis directions, controlled by an electric motor, while the printing
bed can move in the Z-axis direction. During the layering process, the nozzle moves
back and forth, following the spatial coordinates of the 3D model in the .gcode file.

Components of FDM
Some of the components of FDM are as follows:

Picture A.1.1 Components of FDM

2
 Product Design and Development
Fused Deposition Modelling

Filament
Filament is the primary material used to create 3D objects using the FDM (Fused
Deposition Modeling) method. Filament is typically placed on a spool holder,
which is located at the top of the printer for direct drive FDM types and on the
side for Bowden types. The filament is usually made of thermoplastic materials
such as PLA, ABS, PETG, TPU, and others. In this practical session, we will use PLA
filament with a diameter of 1.75 mm.

Extruder
Extruder is the component responsible for pulling the filament from the spool
and feeding it into the printer head. It consists of a motor and drive gears. In
Bowden-type FDM printers, the extruder is mounted externally and connected to
the printer head via a PTFE tube. In contrast, in direct drive systems, the extruder
is located directly on the print head, close to the printer head itself. The extruder
must provide consistent pressure to ensure smooth and continuous flow of
filament.
Printer Head
The printer head is where the filament is melted and extruded to form the
printed object. It consists of several parts including the heater cartridge,
thermistor, heat break, heat sink, and nozzle. The heater cartridge raises the
temperature of the nozzle to melt the filament, while the thermistor monitors
and regulates this temperature. The heat break and heat sink help prevent heat
from traveling upward and causing jams. The melted filament is pushed through
the nozzle in precise amounts and deposited layer by layer onto the print bed.
Print Bed
The print bed is the surface on which the object is printed layer by layer. It usually
moves along the Y-axis (forward/backward). Print beds come in various materials
with different characteristics, such as glass, carbon-coated surfaces, or magnetic
flexible plates. A bed heater is located underneath the print bed to prevent
warping and to improve the adhesion of the first layer.
Bed Levelling Knob
To achieve high- uality prints, bed leveling is necessary. Bed leveling ensures that
q

the distance between the nozzle and the print bed is neither too close nor too far.
This process is performed by turning the knobs located underneath the print bed
to adjust its height manually.

3
 Product Design and Development
Fused Deposition Modelling

LCD Screen
The LCD screen serves as the main interface for controlling and monitoring the
3D printer. It displays real-time information such as the nozzle's position on the X,
Y, and Z axes, the nozzle temperature, the bed temperature, and the current print
progress. In addition to providing visual feedback, the LCD screen offers several
machine control options accessible through its menu system. These include
Motion to move the print head or home the axes, Temperature to adjust and
monitor nozzle and bed temperatures, Configuration for tuning machine
parameters such as step settings or PID values, and Change Filament to load or
unload filament with automated heating. Other menu options include Language
to change the interface language, Release or Print from Card to begin or stop a
print job from an inserted SD card, and About Printer to display system
information such as firmware version and printer details. Some 3D printers come
with a touchscreen interface for easier navigation, while others use a rotary knob
or push-button controls.

Micro SD Card Reader/Input Reader

This is the input method through which the printer receives print jobs. Users slice
their 3D models (usually in STL format) into G-code using slicing software, and
then save this G-code onto an SD card. Input methods may vary depending on
the printer brand, some use SD cards, micro SD cards, or even wireless
transmission via dedicated applications. The printer reads this file and executes
the commands line-by-line to build the object.

Power Supply
The power supply converts AC voltage from a wall outlet into the required DC
voltage used by the printer components. It powers the stepper motors, heating
elements, mainboard, and fans. A stable and sufficient power supply is crucial to
avoid print failures, thermal runaway, or hardware damage.

Type of FDM
A Based on Extruder Systems
Based on the extruder system, FDM can be classified into two types: direct
FDM and Bowden FDM.

4
 Product Design and Development
Fused Deposition Modelling

Picture B.1.1 Classification of FDM Based on the Extruder System

Comparison
Here’s a comparison between direct and bowden extrusion systems:

5
 Product Design and Development
Fused Deposition Modelling

B Based on Heads and Feed Mechanism

Picture B.2.1 Classification of FDM Based on Heads and Feed Mechanism

Based on the heads and feed mechanism, FDM can be classified into three types,
which are Single Head, Dual Head, and In-Nozzle Impregnation.
Single Head Method
This is the most traditional and commonly used method, where only one filament
is extruded through a single nozzle during the printing process. It is suitable for
simple prints using a single type of material and color. The single-head method is
typically used in basic FDM applications and educational practicum due to its
simplicity, low cost, and ease of operation. However, it lacks the ability to
combine materials or colors in a single print.

Example: Haltech H-01, Ender 3-Max, Bambu lab X1 Carbon

Dual Head Method
This method employs two separate nozzles or extruders, allowing the use of two
different filaments either of different colors or different material properties. It
enables more complex printing capabilities, such as combining rigid and flexible
materials or using a soluble support material like PVA for intricate overhangs and
hollow structures. Common applications include producing functional prototypes,
multi-material components, and geometries that require internal support. The
dual-head method generally allows for faster and more efficient printing
compared to switching filaments manually.

Example: Ultimaker S5
6
 Product Design and Development
Fused Deposition Modelling

In-Nozzle Impregnation
This advanced method integrates reinforcement materials (e.g., carbon fiber,
glass fiber, or metal particles) into the filament directly within the nozzle during
the extrusion process. The result is a composite material that offers significantly
improved mechanical strength, stiffness, and durability, suitable for industrial or
functional parts.

Example: Anisoprint Composer A4

C Based on Direction
FDM (Fused Deposition Modeling) printers can be classified based on the
movement system that defines how the print head and/or build platform
operates in space.

Picture B.3.1 Classification of FDM Based on Direction

Rectilinear XZ-Head FDM

This type of FDM printer operates on a Cartesian coordinate system where the
print head moves along the X and Z axes, while the bed moves along the Y axis. It
is one of the most common mechanical layouts due to its simple design and ease
of use. Machines that use this system are typically stable and reliable, making
them ideal for both beginners and professionals. 

Example: Prusa i3

7
 Product Design and Development
Fused Deposition Modelling

R ectilinear XY-Head FDM

In this variation, the print head moves along the X and Y axes, and the bed moves
vertically on the Z axis. This setup allows for faster and smoother horizontal
movements since the print head is not burdened with lifting the object.

It is commonly used in high-precision printers that require consistent detail

across the horizontal plane. 

Example: Ultimaker S5
Core XY FDM
CoreXY is a more advanced Cartesian design that uses a crossed belt system to
drive the print head along the X and Y axes. This allows for precise and high-
speed movement with minimal vibration. The print bed usually moves only along
the Z-axis, resulting in a very stable and accurate print process

Example: Bamboo Lab P1P, Ender K1 Max

Delta FDM
Delta printers feature three vertical arms that work together to position the print
head through triangulated motion. This design allows for fast movement, low
inertia, and tall print volumes. However, due to their complex kinematics, delta
printers can be challenging to calibrate and are not always suitable for parts with
sharp corners or flat surfaces.

Example: Haltech D-01

Belt FDM
Belt printers use a continuous conveyor belt as the build platform, typically
angled at 45 degrees. This allows the printer to produce objects of theoretically
infinite length, which is ideal for batch production or long structural prints. It also
enables automatic part ejection.

Example: Creality CR-30

8
 Product Design and Development
Fused Deposition Modelling

FDM Printing Process

A Pre-Processing
The pre-processing stage begins with designing the 3D object using CAD
software such as AutoCAD, Fusion 360, or other similar programs. Before
printing, the 3D model file must be saved with .stl format and sliced with slicer
application. During the slicing process, various settings are configured,
including object settings, material settings, printer settings, and many others.
These parameters will affect the mechanical properties of the final printed
product. The result of the slicing process is saved in .gcode format, which is a
computer numerical control code that will control the extrusion process.

B Processing
In the processing stage, the filament connected to the nozzle is heated to a
semi-liquid state at temperatures ranging from 150 to 300 ℃. This filament will
form 2D layers on the printing platform, stacking on top of each other to create
a 3D object with dimensional accuracy of 100 µm. Before printing the object,
there is a support base that will be printed first. Supports are additional parts
that are used to support 3D object layers that are floating or do not have
structure below them. 

C Post-Processing
During the post-production stage, the product is removed from the printing
platform and the support is removed from the product. This stage is an
important process because the results of 3D printing are generally not ready
for immediate use. This process is used to improve the quality of the product's
surface. There are two methods used: mechanical methods (machining,
sanding, cutting, etc.) and chemical methods (painting, coating, etc.)

Material
Materials commonly used in FDM are polymer-based with different physical,
mechanical, and thermal properties. The selection of polymer materials is tailored to
the requirements of FDM applications. However, the currently available types of
polymers are still limited. Commercially available FDM machines have a melting point
capability of around 300°C, making high melting point materials incompatible for use

9
 Product Design and Development
Fused Deposition Modelling

on available machines. Therefore, thermoplastic polymers and other low melting

point materials are used in FDM machines. Various efforts have been made to
improve the quality and properties of polymers by adding fillers such as ceramics,
nanoparticles, metals, and wood fibers. Here are two commonly used materials in
FDM:
Polymers
In 3D printing, polymers are the most commonly used materials for creating
prototypes or products. Pure polymers such as acrylonitrile butadiene styrene
(ABS), polylactic acid (PLA), and polyamide (PA) are often used for prototyping due
to their favorable physical properties. On the other hand, polyethyleneimine (PEI),
polyetherketoneketone (PEKK), polystyrene (PS), and polyetheretherketone (PEEK)
are used for components requiring superior mechanical, thermal, and chemical
resistance properties. The type of polymer used in this practicum is PLA. PLA is an
environmentally friendly material made from beet sugar and corn with the
characteristics of being biodegradable, compostable, and non-toxic. PLA is a low-
temperature thermoplastic, so it has low operating costs with good mechanical
properties. However, low melt strength and slow crystallization rate are the main
limitations of this material. ABS is an oil-based material widely used for its high
mechanical strength, ease of processing, corrosion resistance, and high melting
strength. ABS is also easily extruded, making it popular for household product
printing. However, ABS cannot be used in medical applications due to its lack of
biocompatibility and non-waterproof layer.

Composite
To achieve specific mechanical properties, different materials can be combined to
form a composite. In general, composites are classified into four types: polymers,
ceramics, fibers, and nanomaterials, which are added to base polymers to produce
composite filaments. Materials that are combined with polymers are classified into
two types: biodegradable and non-biodegradable. Biodegradable materials that
can be used include biodegradable polymer blends, polymer-ceramic composites,
natural fillers, and natural fibers. Non-biodegradable materials that can be used
include non-biodegradable polymer blends, polymer-metal composites, fiber-
reinforced composites, and nanocomposites.

10
 Product Design and Development
Fused Deposition Modelling

Advantages

Affordability and Accessibility

FDM 3D printing stands out for its affordability and widespread availability,
making it an ideal option for individuals, educators, and startups.

User-Friendly Operation and Simple Maintenance

FDM printers are relatively easy to operate and maintain, with minimal setup and
ongoing maintenance requirements.

Safety and Environmental Friendliness

The FDM process is relatively clean and safe, not requiring the use of harsh
chemicals or generating harmful fumes.

Diverse and Inexpensive Materials

A wide range of affordable and readily available thermoplastic filaments are
compatible with FDM printers, allowing for flexible material choices in various
applications.

Design Flexibility
FDM printers can accommodate a wide range of design complexities, from simple
objects to intricate parts with minimal design modifications.

Scalability
FDM printing systems can be scaled up or down with ease, ranging from desktop
sized units for personal use to larger industrial machines for high-volume tasks.

Limitations

Model Strength and Anisotropy

FDM-printed models may not be fully solid due to the layer-by-layer deposition
process, leading to anisotropic properties with weaker inter-layer bonds
compared to intra-layer bonds.

Surface Quality
FDM printers generally produce lower surface quality compared to other 3D
printing methods, with visible layer lines and potential for dimensional errors,
warping, and surface imperfections.

11
 Product Design and Development
Fused Deposition Modelling

Fine Detail Limitations

Achieving high-resolution details can be challenging with FDM printing due to the
nozzle size and layer height limitations.

Thin Wall Challenges

FDM printing is not well-suited for producing thin-walled structures, as they may
be prone to warping or failure. A general rule of thumb suggests a minimum wall
thickness of 1mm for horizontal/vertical walls, while curved and angled walls may
require thicker walls.

Material Restrictions
FDM printing is primarily limited to thermoplastic materials and thermoplastic-
based composites. Printing with metal or ceramic materials may require
specialized filaments and post-processing steps, and the resulting parts may not
be fully dense.

Noise Challenges
FDM printers can be noisy during operation.

Waste Management Requirements

Support structures are often required for complex geometries, which can
generate waste material.

Slower Process
Build speed may be slower compared to other 3D printing methods for certain
applications.

Application
FDM can produce almost any geometry that can be designed. Due to the many
advantages of this method, there are many potential applications for FDM parts
including aerospace, electronics, biomedical, construction, automotive and other
sectors. 

12
 Product Design and Development
Fused Deposition Modelling

Picture G.1.1 Examples of FDM application (a) Evector aircraft components and line adapters (b)
Electrical circuit with LEDs (c) Human ribs replacement (d) FDM concrete molding process and
the first FDM printing by WinSun company in 2014 (e) Lightweight engine cover made using 3D
printing technology produced by BMW

(a) Aerospace
The aviation industry has always been costly due to the many iterations of
design for large products and production limitations. For this reason, FDM can
be an alternative to produce parts without any tool modification and low
volume production. In the picture above (picture a), Bell Helicopter's V-22
Osprey polycarbonate Evector and cable pipe aircraft components made using
FDM have been proven to be robust enough to withstand the terrain and have
been produced with a significant reduction in production time.

(b) Electronics
Polymer composites produced by FDM can act as electronic instruments and can
be used in various forms in combination with leading electrical materials. The
picture above (picture b) shows an electric circuit produced by FDM with an LED.

(c) Biomedics
Special requirements for biomedical applications such as high complexity, ease
of access, small production quantities, patient-specific needs, and customization
have been the driving factors for FDM technology.

13
 Product Design and Development
Fused Deposition Modelling

In the picture above (picture c), one application of the FDM method in this field
can be seen in the form of replacement ribs for humans.
(d) Construction
Casting, molding, and extrusion are traditional methods in the construction
industry. 3D printing can be used in the construction industry where limitations
such as geometric complexity and hollow structures are required. The figure
above (picture d) shows the process of FDM concrete printing and the first FDM
printing by WinSun Company in 2014.

(e) Automotives
The FDM process is frequently used in the automotive sector for the
development of prototypes and functional prototypes. The figure above (picture
e) shows a lightweight engine cover made using 3D printing technology
produced by one of the largest car manufacturers, BMW.

Other Sectors
The FDM process is also commonly utilized in various other fields to create
prototypes, functional models, architectural designs, jewelry, toys, household
items, and finished consumer products.

Defect

Picture H.1.1 Examples of Defect (a) Printout sticks too much to the build plate (b) Warping (c) 1.
Under Extrusion (c) 2. Over Extrusion (d) Unprintable Features (e) Poor Surface Above Supports
(f) Vibrations/ Ghosting/Ringing (g) Blobs (h) Stringing (i) Elephant Foot

14
 Product Design and Development
Fused Deposition Modelling

(a) Printout sticks too much to the build plate

The main problem that can be caused by such defects is that it is difficult to
remove the model from the build plate without damaging both in post
processing/production. More force is required even if the scraping tool used is
appropriate. This can be frustrating or even dangerous for the practitioner.

The main cause of this problem is the nozzle being too close to the build plate
nozzle which is a failure in the bed leveling process. The nozzle that is installed
too close to the build plate is the reason the first layer of the mold becomes too
attached to the build plate. 

The solution is to use thicker paper during bed leveling and adjust the nozzle
that is too close to the build plate by loosening the bolts. In addition, it is also
possible to adjust factors that can increase bed adhesion such as adjusting the
bed temperature.

(b) Warping
Warping is characterized by the mold lifting (usually starting from the edge
corner) and peeling off the bed. This occurs because the mold material layer
cools too quickly after molding to exceed the adhesion strength of the model on
the build plate.

Possible solutions include balancing the molding temperature with room

temperature, printing with thinner layers, and ensuring the bed temperature is
not too close to the filament transition temperature.

(c) Under Extrusion and Over Extrusion

Under Extrusion occurs when the printer nozzle cannot eject enough filament,
resulting in incomplete or weak prints. Under extrusion is characterized by
missing print layers, gaps/holes, or thin prints. This problem can be caused by
factors such as technical errors in the machine, filament or print settings. These
factors cause the filament extrusion flow to not be smooth.

The solution that can be done is to overcome the factors that cause disrupted
flow such as routinely cleaning the feeder to prevent debris from accumulating,
ensuring the cooling fan so that there is no nozzle blockage. In addition, filament
maintenance is needed so that it does not get stuck easily and the most
important thing is to adjust the flow rate on the slicer so that it is not too low.

15
 Product Design and Development
Fused Deposition Modelling

On the other hand, over extrusion is characterized by excessive filament

extrusion that can cause other problems such as stringing and blobs. Over
extrusion can be caused by temperatures that are too high and flow rates that
are too high. A possible solution is to improve the printing settings on the slicer.

(d) Unprintable Features

The majority of 3D printers are equipped with a fixed nozzle size that
determines the resolution of printed parts in the XY direction. A common nozzle
size is 0.4mm in diameter, which is suitable for most prints. However, difficulties
may arise when attempting to print exceptionally thin features that are smaller
than the nozzle size.

One approach is to redesign the part to have thicker features by modifying the
3D model using any 3D modelling software to adjust the size of the smaller
features. Thickening the thin features is necessary if the aim is to print a feature
with a thickness of 0.2mm using a 0.4mm diameter nozzle. There might be an
observation where this thin feature does not appear in any slicer or may not be
accurately represented in the final print if the areas are not thickened to more
than 0.4mm.

(e) Poor Surface Above Supports

Slicing softwares offers remarkable advantages through their capabilities to
generate innovative support structures, enabling the creation of intricate and
complex parts that would be challenging to manufacture. These support
structures play a crucial role in providing a foundation for steep overhangs or
areas of the model without any underlying structure. 

The support structures generated are designed to be disposable and can be

easily removed from the final part. One way to prevent this defect is to reduce
the layer height from 0.2mm to 0.1mm. This adjustment results in the printer
generating twice as many layers for the same object. Consequently, the printer
can take smaller steps when creating an overhang, thereby enhancing the
precision and accuracy of the printed structure.

16
 Product Design and Development
Fused Deposition Modelling

(f) Vibrations/ Ghosting/Ringing

Caused by vibrations that distort the wall with a shaded or wavy effect, ruining
the aesthetics of the print. The main cause of this problem is the instability of
the printer's movement during the printing process due to a loose build plate or
a slicer setting error due to too high acceleration and speed and too many
changes in direction to match the model during the printing process.
(g) Blobs
Blobs are unwanted bubbles of excess extruded filament on the shell of a
molded model that should look smooth and clean, damaging the surface finish.
Extruders that repeatedly stop and move during the molding process cause
blobs due to inconsistent material flow changes. This can be caused by several
factors such as improper retraction, high feed rate and speed. The solution is to
improve the slicer settings especially on speed, cooling, sheel, and retraction.

(h) Stringing
This problem is characterized by a thin thread/string of printed material
appearing in the space between the die sections. Stringing can occur due to the
filament continuing to flow as the extruder moves between two adjacent die
sections or as the extruder moves from one point to another without printing
(traveling). The solution is to increase the retraction distance and retraction
speed and increase the cooling and travel speed of the slicer. 

(i) Elephants Foot

Characterized by the first layer of the model appearing to curve upwards, bulge,
or bubble causing it to appear larger than the layer above the model. This
happens because the bottom of the molded object is located very close to the
build plate and receives extra pressure from the mold material which is still in a
hot and liquid state. The solution is to increase the distance between the nozzle
and the bed and increase the cooling fan on the slicer.

17
 Product Design and Development
Fused Deposition Modelling

Slicer
For anyone venturing into FDM (Fused Deposition Modeling) 3D printing,
understanding the function of a "slicer" is fundamental. This essential piece of
software acts as the critical translator between your digital 3D model and the
physical object that will emerge from your printer. Without it, your 3D printer would
have no instructions on how to construct the desired part.

At its core, a 3D printing slicer takes a 3D model file – commonly in formats like .STL,
.OBJ, or .3MF – and digitally "slices" it into hundreds or thousands of thin horizontal
layers. It then generates a file, typically in a language called G-code, which provides
the precise, layer-by-layer instructions your FDM printer needs to follow. This G-code
dictates every movement of the print head, the rate of filament extrusion,
temperature settings, print speed, and much more.

Popular Slicer Software for FDM Printing:

The FDM 3D printing landscape offers a variety of slicer software options, many
of which are free and open-source, while others are commercial products. Some
of the most widely recognized and utilized slicers include:

UltiMaker Cura
Developed by UltiMaker, Cura is a highly popular, free, and open-source slicer
known for its user-friendly interface and extensive customization options. It
supports a vast range of 3D printers.

PrusaSlicer
Originating from rusa esearch, rusaSlicer (based on the earlier Slic3r) is
P R P

another powerful, free, and open-source option. It s lauded for its advanced
'

features, regular updates, and strong community support. It also includes

profiles for many third-party printers .

Creality Print
Developed by Creality, this slicer is often recommended for users of Creality
3D printers, offering a tailored experience.

Anycubic Slicer
Similar to Creality rint, Anycubic provides its own slicer optimized for its
P

range of FDM printers

18
.

 Product Design and Development

Fused Deposition Modelling

OrcaSlicer and Bambu Studio

These newer slicers have gained significant popularity, with Bambu Studio
being developed by Bambu Lab for their printers (though it can often be used
with others) and OrcaSlicer being a fork of Bambu Studio with broader
compatibility and additional features.

Slic3r
One of the original open-source slicing projects, Slic3r laid the groundwork for
many modern slicers and is still used and developed by a dedicated
community.

Simplify3D
A commercial slicer known for its powerful features, granular control over the
printing process, and excellent support generation.

Choosing the right slicer often comes down to user preference, the specific 3D
printer being used, and the complexity of the prints being undertaken. Many users
experiment with multiple slicers to find the one that best suits their workflow and
provides the desired results. However, for this particular lab session, we will be
specifically using UltiMaker Cura software for the slicing process.

19