Fused filament fabrication, also known as FFF 3D printing, is an (AM) additive manufacturing process in which thermoplastic material is fed through a heated nozzle to build things one layer at a time.
The FFF technique was first developed in the late 1980s and later commercialized. S. Scott Crump was granted U.S. Patent Number 5,121,329, entitled Apparatus and Method for Creating Three-Dimensional Objects, on July 6, 1991. It was assigned to Stratasys, Inc., which received it on June 9, 1992.
The technology was first patented in 1988 by Stratasys, who brought it to market with a range of 3D printers including the FDM 300, FDM Maxum, and FDM Titan. Other businesses are now free to sell items based on this innovation after the patent expired, although Stratasys still has trademark rights.
What Is FFF 3D Printing?
Desktop FFF was originally invented in the 1980s as a proprietary manufacturing technique, but it really took off roughly 10 years ago, when patents initiatives expired such as the RepRap initiative of open-source promoted more affordability and innovation.
Today, FFF technology is typically a more cost-effective option than other 3D printing technologies both in terms of initial investment and ongoing expenses. It’s also well regarded for being simple to comprehend and use, making it particularly appealing to busy engineers and primary school kids.
But it has shown to be so dependable, accurate, and capable of generating strong components over the years that most of the world’s major manufacturing, design, and education firms now use it to generate new ideas.
How Does FFF Work?
The material is extruded from a machine using the FFF process, which consists of a melted plastic extrusion process. A print head travels around the printing surface depositing material to produce the component.
- The first stage is to create the 3D model with any design program, such as Solidworks or Catia. The STL version of the 3D model must be exported.
- The model is sliced using a slicing program that includes all printing demands in file preparation. The material choice and nozzle size will be included in this setting. The program also divides the model into layers, and you may customize the print quality and movement commands.
- The printing process is the laying down of melted plastic.
FFF 3D Printing Uses
- Manufacturing: FFF 3D printing is utilized in a wide range of industries, owing to faster lead times and a variety of engineering materials than outsourcing. In manufacturing sectors, 3D printers provide rapid tooling and replacement components to ensure that the production line runs continuously and efficiently. They’re also used to rapidly produce end-use components. Like bespoke high-quality gauges or small batch first runs, to reduce time to market.
- Prototyping: FFF 3D printing is especially useful for the iterative design process because of its low-cost materials and short print times. FFF prototypes may be used to conceptually demonstrate ideas or test technical components physically.
- Education: FFF hardware is inexpensive and simple to use, allowing for a wide range of educational applications – from engaging younger kids with STEAM fundamentals to offering production labs for college and university students to work on engineering projects and acquire skills for the modern workplace.
Benefits Of FFF:
- In addition to a wide range of thermoplastics, wood and metal-infused thermoplastics, and even food. You’ll find everything you need right here.
- The lowest-cost printer technology.
- The materials that are the least expensive.
- Switching from one material to another is simple.
- It is possible to print on a variety of materials.
- Many manufacturers provide printers and materials.
- It is quite simple to construct your own printer.
- Quick printing.
Disadvantages of FFF:
- The size of the nozzle limits the detail in the end prints. Other technologies, on the other hand, can produce higher-resolution images.
- Because each layer is coupled to the layer below it, the overall strength of produced components is restricted.
FFF Materials
The most prevalent materials employed in FFF manufacturing are polymers, which have a wide range of applications.
Fibers of carbon, metal, glass, or other materials are sometimes used to make composite materials that offer structural advantages. Although these cannot be printed consistently on all FFF 3D printers, they are utilized in a number of applications.
Technologically, it is feasible to biological pastes and print food using 3D printing technology. Albeit it is typically done for experimental or research purposes. Support material, which is another important category of FFF materials, is used to support or help hold the shape or position of a part.
When it’s impossible to print from bottom to top because the orientation or form of a component prevents it. For example, when a part has a large overhang, support materials are designed to be simple to remove.
Depending on the type of 3D printer you want to buy, PLA or ABS is generally preferred. For FFF 3D printers, the filament is sold as spools, which contain from 250 g to 1 kg of material. Always double-check the compatible materials if you’re thinking about purchasing a 3D printer.
Some printers may be limited to utilizing two or three materials. While some printers claim to work with any material. They soon have technical difficulties as a result of printing abrasive composite materials. Some FFF 3D printers are restricted to using the manufacturer’s proprietary materials only. While others (like Ultimaker) have an open filament system that works with third-party goods.
PLA (polylactic acid), which is frequently used as a “beginners” material due to its simplicity of use, and ABS (acrylonitrile butadiene styrene). Which has better mechanical properties and heat resistance, are two of the most frequently used FFF 3D printing polymers.
FFF 3D Printers
Despite the fact that all FFF 3D printers are based on the same manufacturing technique, their capabilities vary significantly.
Another distinction to consider is material compatibility (see above). With the hardware being particularly significant in determining what kinds of composite materials may be produced.
Another important distinction between FFF 3D printers is their size. The printable area, often known as the build volume or building envelope, determines how big a single print or batch can be. The printer’s build platform is where the two parts that make up the 3D printer are welded together.
It may range from 10 cm (3.9 inches) of printable space in the X, Y, and Z dimensions. To around 1 m (39 inches) in one or more of these dimensions for the biggest units. Because large format printers often necessitate a loss in quality, keep this in mind when you’re buying one.
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