Fused Deposition Modelling (FDM) 3D Printing Service
Our FDM 3D Printing Service
| Materials | Price | Dimensional Accuracy | Strengths | Build Volume | Layer Thickness | Min. Feature Size |
|---|---|---|---|---|---|---|
| Industrial SLA | $$$ | ± 0.2% with a minimum of ± 0.13 mm | High precision, fine details, large part capability | 500 × 500 × 500 mm (19.68"³) | 50-100μm | 0.2 mm (0.00787") |
| Industrial FDM | $$$$ | ± 0.3% with a minimum of ± 0.3 mm | Excellent repeatability, ideal for engineering materials | 406 × 355 × 406 mm (15.98"³) | 100-330μm | 2.0 mm (0.0787") |
| FDM (Large Format) | $$$ | ± 0.3mm | Cost-effective, broad material compatibility, extra-large build area | 750 × 750 × 750 mm (29.5"³) | 100-300μm | 2.0 mm (0.0787") |
| MJF | $$ | ± 0.3% with a minimum of ± 0.3 mm | Supports complex geometries without additional structures | 380 × 285 × 380 mm (14.9"³) | 80μm | 0.5 mm (0.0196") |
| SLS | $$ | ± 0.3% with a minimum of ± 0.3 mm | Freeform design freedom, no need for support structures | 395 × 500 × 395 mm (15.53" × 19.68" × 15.53") | 100μm | 0.5 mm (0.0196") |
| Prototyping SLA | $$ | ± 0.3% with a minimum of ± 0.3 mm | Fine surface textures, sharp detail reproduction | 145 × 145 × 175 mm (5.7"³) | 50-100μm | 0.2 mm (0.00787") |
How Fused Deposition Modeling (FDM) Printing Works
FDM is a 3D printing technique that uses thermoplastic filament as its material source. The filament is unwound from a spool and pushed into a heated print head, where it melts. The softened material is then extruded through a fine nozzle, forming a thin, continuous bead that creates each layer of the object. After cooling and solidifying, the build platform lowers incrementally to allow the next layer to be printed, repeating the cycle until the final part is complete.
In addition to the main build material, a secondary filament can be deposited simultaneously to create temporary support structures. These supports are later removed either by dissolution or mechanical means once the printing is finished.
FDM parts are recognized for their strength, durability, and dimensional accuracy. At KingStar Mold, we also offer a range of professional post-processing services to tailor the final parts to your specific application needs.
FDM Materials
Explore a full range of high-performance FDM materials designed to meet diverse application requirements across industries.
Our FDM materials offer a wide range of performance characteristics, from high strength and heat resistance to flexibility and chemical stability. Whether you need tough, durable parts for industrial use or specialized thermoplastics for medical, aerospace, or commercial applications, our selection ensures reliable, high-quality results tailored to your project needs.
Typical Applications
Workholding Tools
FDM offers a fast and cost-effective solution for producing custom jigs, fixtures, and tooling aids used across manufacturing lines.
Aviation and Aerospace
Lightweight, strong FDM parts are increasingly replacing traditional metal components, with common applications including cabin interior parts and under-the-hood engine elements.
Rapid Prototyping
Thanks to the strength and durability of FDM materials, prototypes can be tested for fit, finish, and performance, helping refine designs before committing to production tooling.
Consumer Goods
The chemical and impact resistance of FDM-printed parts makes them well-suited for a wide range of consumer products that require everyday durability.
Production Parts
Certain FDM materials offer excellent chemical resistance and durability under extreme conditions, making them ideal for low-volume production in aerospace, automotive, and industrial sectors.
Medical Devices
FDM technology supports the creation of surgical tools, prosthetics, dental models, and hearing aids, where strength, sterilization capability, and biocompatibility are critical.
FDM Finishing Options
| Surface Finish | Applicable Materials | Colors | Description |
|---|---|---|---|
| Sanded | All | – | Manual or machine sanding to smooth surfaces and reduce visible layer lines |
| Tumbled | All | – | Polishing process using abrasive media to deburr and slightly smooth parts |
| Media Blasted | All | – | Matte finish achieved by blasting parts with fine media, ideal for consistent texture |
| Vapor Smoothed | ABS, ASA | – | Chemical vapor treatment melts outer layer for glossy, sealed surfaces |
| Painted (EMI Shield) | ABS, PC, PC-ABS | Silver, Metallic | Specialized conductive paint to provide electromagnetic interference shielding |
| Painted (Sand and Paint, Non-Cosmetic) | All | Black, Gray | Basic sanding and painting focused on functionality rather than perfect appearance |
| Painted (Sand and Paint, Cosmetic) | All | Pantone/RAL colors | High-quality sanding and painting process for visible, aesthetic parts |
| Painted (Customer Spec Paint) | All | Custom Colors | Painting according to specific customer color or finish requirements |
| Specialty Coated | All | Varies | Application of specialty coatings like UV resistance, anti-scratch, or soft touch |
| Plated | ABS | Metallic | Electroplating adds thin metal coating for strength, wear resistance, and aesthetics |
| Decals | All | Printed Graphics | Applying stickers or labels for branding, instructions, or markings |
| Pad Printed | All | Pantone Colors | Precise transfer of small logos, icons, or texts via pad printing |
| Screen Printed | All | Pantone Colors | Printing larger graphics or labels directly onto part surfaces |
| Inserts | All | – | Installation of metal inserts for threads, fasteners, or structural reinforcement |
| Post-Machined | All | – | Machining processes like drilling, milling, or reaming to achieve fine tolerances |
| Assembly | All | – | Final assembly operations, combining multiple printed and non-printed parts |
About the Process
Fused Deposition Modeling (FDM) 3D printing is an additive manufacturing process that builds parts layer by layer from a thermoplastic filament. The filament is fed into a heated print head, where it melts and is extruded through a fine nozzle onto the build platform. As each layer is deposited, the material cools and solidifies, forming a strong bond with the previous layer. The build platform gradually moves to accommodate new layers until the complete part is formed. FDM is widely valued for its ability to produce durable, functional prototypes and end-use parts across a range of industries.
Design Guidelines
When designing for FDM 3D printing, it’s important to account for the process’s specific characteristics to ensure successful, high-quality parts. Key considerations include optimizing wall thickness, adding proper draft angles, minimizing unsupported overhangs, and designing with material shrinkage and layer adhesion in mind. By following proven FDM design guidelines, engineers can enhance part strength, dimensional accuracy, and surface quality while reducing the risk of print failures.
Advantages of FDM 3D Printing
Frequently Asked Questions
While FDM 3D printing is highly effective for prototyping and low-volume production, it is typically not used for large-scale mass production due to speed limitations compared to traditional manufacturing methods. However, it is ideal for producing customized parts or small batches.
The duration of the FDM 3D printing process varies depending on the size and complexity of the part. Generally, FDM prints are completed in a matter of hours to days. Larger parts with intricate geometries may take longer to print, while simpler parts can be printed quickly.
We combine industrial-grade equipment, extensive material options, large-format capabilities, and rapid turnaround to deliver high-quality FDM parts tailored to your project needs.
FDM (Fused Deposition Modeling) is a widely used 3D printing technology that builds parts layer by layer by extruding a thermoplastic filament through a heated nozzle. Compared to other additive manufacturing methods like SLA (stereolithography) or SLS (selective laser sintering), FDM is known for its material versatility, cost-effectiveness, and ability to create durable, functional prototypes and end-use parts. Unlike resin-based processes that cure liquid photopolymer or powder-based processes that fuse fine powders, FDM directly melts solid filament, making it cleaner, easier to handle, and ideal for producing larger parts with industrial-grade materials. This process supports a broad range of engineering thermoplastics and is favored for its scalability, strength, and rapid prototyping capabilities across various industries.
