Fused Deposition Modelling

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FDM is the workhorse process for functional parts. It’s normally the most cost-effective way to produce durable prototypes, brackets, mounts, housings, and short-run parts without tooling.

What is FDM?

Fused Deposition Modeling, or FDM, is the most widely used type of 3D printing. FDM printers work by heating a thermoplastic filament to its melting point and then extruding it, layer by layer, to create a three dimensional object.

FDM printers are relatively inexpensive and easy to use, making them a popular choice for home and small-scale 3D printing. However, FDM printing is not without its limitations. The main drawback of FDM printing is that it is relatively slow compared to other 3D printing technologies.

Another limitation of FDM printing is the range of materials that can be used. Thermoplastics are the only type of material that can be used with FDM printers. This limits the range of objects that can be printed with FDM technology.

Despite its limitations, FDM printing remains the most popular type of 3D printing due to its affordability and ease of use.

Brackets, housings, mounts, covers and functional prototypes
Jigs and fixtures for workshop or manufacturing use
Short-run parts where injection moulding isn’t viable

The part that matters most

The material choice usually makes a bigger difference than the printer itself. Tell me the environment (heat, load, chemicals, outdoors) and we’ll pick the right option.

If you want it to look perfect

If your priority is surface finish and fine detail over strength, we can talk about SLA instead. FDM can look excellent, but it’s fundamentally a layered process.

How we approach an FDM job

If you’ve got CAD, great — send it over. If you don’t, a good photo and a few measurements often gets us most of the way there.

From there we’ll confirm orientation, strength direction, tolerances, and what matters most: fit, finish, or durability.

Fused Dispositioning Moulding, also known as FDM, is a 3D printing process that is becoming increasingly popular for both home and industrial use. FDM works by melting a filament of plastic and extruding it through a small nozzle. The plastic is then layered on top of itself to create a 3D object.

There are many advantages to using FDM over other 3D printing processes. One advantage is that FDM is much cheaper than other processes. This is because FDM printers are relatively simple to build and the plastic filament is relatively inexpensive.

Another advantage of FDM is that it is very versatile. FDM printers can print in a wide variety of materials, including PLA, ABS, PETG, and even metal. This makes FDM an ideal choice for printing objects that need to be strong or heat-resistant.

Finally, FDM is relatively easy to use. Most FDM printers come with easy-to-use software that makes it simple to create 3D models. Once the model is created, the printer does the rest of the work.

Overall, FDM is a great choice for 3D printing. It is relatively inexpensive, versatile, and easy to use. If you are looking for a 3D printing process for your home or business, FDM is a great option to consider.

Technical Specifications (FDM)

▸ Layer Height: • 0.1 mm – 0.4 mm (depending on nozzle size) • Coarser layers = faster prints, finer layers = better surface finish ▸ Materials: • PLA, ABS, PETG, TPU (flexible), Nylon • Carbon fibre, glass-filled, wood, and more ▸ Mechanical Strength: • Infill adjustable from 0% to 100% for strength optimisation • Ideal for stress-bearing parts and tool-grade applications ▸ Print Size Capabilities: • Up to 600mm x 600mm x 600mm (larger with modular builds) ▸ Finish: • Matte or semi-gloss depending on filament • Optional post-processing: sanding, resin-coating, vapor smoothing Whether you need a strong bracket, housing, or low-run production part — FDM’s flexibility offers a scalable solution. And with our design-for-manufacture knowledge, you’ll always get optimal strength-to-cost ratio.

Real-World Use Cases

1. Functional Prototypes for Engineering Teams Prototypes that can be tested, stressed, and iterated quickly — that’s where FDM shines. • Enclosures with snap fits • Mechanical test parts (mounts, brackets, gears) • Ergonomic evaluation of tool designs 2. Custom Tools, Jigs & Fixtures Forget paying thousands for machined jigs. With FDM, we deliver: • Production aids in days, not weeks • Tailored fitment for assembly lines • Cost-effective replacements for legacy parts (even discontinued) Example: We replicated an old train lever clip in ABS for a restoration project where no replacement parts existed — saving the client thousands compared to moulding. 3. Manufacturing Bypasses & Short-Run Production FDM bridges the gap between prototyping and full production: • Custom low-volume runs • Stop-gap solutions for supply chain delays • Low-cost tooling or internal-use components And because FDM supports up to 100% infill, you get near-solid parts without the cost of metal machining.

Where is FDM 3D Printing used?

FDM 3D printing is a technology that works both horizontally and vertically, where an extrusion nozzle moves over a build platform. The process involves the use of thermoplastic material that reaches melting point and is then forced out, to create a 3D object layer by layer. In the early days of automobile production, engineers and designers would often create prototypes by hand. This was a time-consuming and expensive process, and it was difficult to create complex shapes. Then, in the 1980s, a new technology called fused deposition modeling (FDM) was developed.

With FDM, a prototype can be created quickly and cheaply. And, since it is an additive manufacturing technique, it can be used to create complex shapes that would be difficult to produce by other means.

Today, automotive 3D printing is used by many different industries, ranging from aerospace to consumer products. It is particularly well-suited for creating prototypes and small batch production runs.

Automotive 3D printing has transformed the automobile industry, allowing manufacturers to test new designs quickly and cheaply. It has also allowed the production of lightweight tools and final functional components.

Thanks to automotive 3D printing, the automobile industry is able to innovate at a faster pace than ever before.