Stratasys FDM (Fused Deposition Modeling) 3D Printer

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3D Printer Brings Kids Into Engineering Lab

This 3D Printer creates excitement for this cutting-edge program.

Was your car built before the turn of the new millennium? If so, chances are you’re among millions of Americans who have share a common problem: ill-fitting cup holders.

Peter Grimm, an industrial technology teacher at Southview Middle School in Edina, MN, has challenged his eighth-grade pre-engineering students to find a solution for this messy problem. And the Dimension uPrint™ Personal 3D Printer is helping students find creative answers.

This model was designed and developed using the Dimension 3D printer to fit properly in an existing car cupholder, thus increasing the functionality of the stock cupholder. Items are printed using durable industrial strength ABS Plastic.

Grimm first saw the educational power of 3D printing earlier in his career when he started a Minneapolis school’s partnership with Project Lead the Way (PLTW). PLTW is a national program that provides curriculum and partnerships with the private sector to increase the quantity and quality of engineers and engineering technologists graduating from our educational system.

Weighing the Options

After transferring from Minneapolis to Edina schools, Grimm started the PLTW partnership at Southview and began investigating the purchase of a 3D printer to enhance the program. While teaching in Minneapolis, Grimm had several years of experience with printers from Dimension and a competitor. “The Dimension printer was just better suited for the educational environment,” said Grimm. “The cost, ease of use, and durability of the printed models produced led me to choose a Dimension 3D Printer.”

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Stratasys Delivers First Shipment of HP-Branded 3D Printers

 

Event marks milestone in agreement to develop 3D printers for HP

MINNEAPOLIS, Apr 19, 2010 (BUSINESS WIRE) --Additive fabrication system maker, Stratasys, Inc., (NASDAQ: SSYS), today announced it has delivered its first shipments of HP-branded 3D printers.

Stratasys and HP co-developed the exclusive 3D printer systems, which are being manufactured byStratasys as part of a global manufacturing agreement with HP (NYSE: HPQ), as announced in January.

HP launched its Designjet 3D products in Europe today, making it the only major manufacturer of 2D (or paper) printers in the 3D printer market. The products will be available this May in five European markets: France, Germany, Italy, Spain and the UK.

"The agreement to develop and manufacture a product to HP's specification is a milestone for us," says Stratasys CEO Scott Crump. "Today, we're taking a big step in realizing the agreement's potential by demonstrating we can deliver."

"There are millions of 3D designers using 2D printers who are ready to bring their designs to life in 3D," says Santiago Morera, HP's vice president and general manager of its Large Format Printing Business. "Stratasys FDM technology is the ideal platform for HP to enter the 3D MCAD printing market and begin to capitalize on this untapped opportunity."

Technology & Use

Product designers, engineers, and architects who design with CAD (computer aided design) use 3D printers as peripheral devices to "print" or produce a tangible 3D model from plastic or other material to verify the form, fit, and function of designs prior to committing them to production or construction. Designers often seek 3D printers that model with production-grade thermoplastic when they want to best-predict performance of their plastic end-product.

Stratasys manufactures 3D printers under the Dimensionbrand, and it makes 3D production systems under the Fortus brand. Both product lines, as well as the HP-branded 3D printers employ Fused Deposition Modeling (FDM) technology, which creates three-dimensional plastic models directly from a CAD file. The patented process creates parts by extruding semi-molten plastic in thin layers to "grow" the part, layer by layer. The process of producing a part layer-by-layer is known generically as "additive fabrication" or "additive manufacturing."

Pioneer & Leader

The term "3D printer" was coined by Stratasys when it introduced its first compact system co-developed with IBM in the mid 1990s. 3D printer is now widely used to describe a segment of additive fabrication machines that generally connotes a compact, low-price unit that is quick and easy to operate. Stratasys was an early pioneer of the additive fabrication industry as well as its 3D printer segment. The company has a seven-year track record as the industry's unit sales leader, and it has an industry market share of 43 percent, as well as a market share of more than 50 percent for the 3D printer segment. The company's ongoing leadership demonstrates customers' long-term satisfaction with its products and FDM technology.

The technology to produce 3D models directly from a digital design has been commercial for more than 20 years, but recent advances in 3D printers have dramatically reduced their cost and improved ease-of-use and reliability. Stratasys introduced its Dimension 3D printer line in 2002, with the first printer priced under $30,000. Early last year, Dimension broke the $15,000 (USD) barrier with its office-friendly uPrint, which fits on a desktop.

HP's Graphic Solutions Business - part of the company's $24 billion Imaging and Printing Group - executed the distribution agreement with Stratasys. HP is a leading provider of Designjet and Scitex large-format printing solutions, Indigo digital solutions for commercial and industrial printing, inkjet high-speed production solutions and specialty printing systems.

Stratasys, Inc., Minneapolis, manufactures additive fabrication machines for prototyping and manufacturing plastic parts under the brands Fortus 3D Production Systems and Dimension 3D Printers. The company operates RedEye On Demand, an online service for part prototyping and production. Stratasys also manufactures 3D printers for HP, sold under the brand Designjet 3D. According to Wohlers Report 2009, Stratasys supplied 43 percent of all additive fabrication systems installed worldwide in 2008, making it the unit market leader for the seventh consecutive year. Stratasys patented and owns the process known as FDM. The process creates functional prototypes and manufactured goods directly from any 3D CAD program, using high-performance industrial thermoplastics. The company holds more than 280 granted or pending additive fabrication patents globally. Stratasys products are used in the aerospace, defense, automotive, medical, business & industrial equipment, education, architecture, and consumer-product industries. Online at:www.Stratasys.com

Dimension, a brand of 3D printers by Stratasys, offers computer-aided-design (CAD) users a low-cost, networked alternative for building functional 3D models from the desktop. The printers build models layer-by-layer using ABS plastic, one of the most widely used thermoplastics in today's injection-molded products. Dimension 3D printers allow users to evaluate design concepts and test models for form, fit, and function. Online at: www.DimensionPrinting.com

Fortus is a brand of Stratasys, Inc., formerly known as the FDM Group. Fortus offers a line of 3D production systems used for direct digital manufacturing and precision rapid prototyping. Fortus systems create manufactured goods or prototypes from industrial thermoplastics, including ABS, polycarbonate, PPSF, blends, and ULTEM* 9085. Online at: www.Fortus.com

Fortus is a trademark, and Dimension, Stratasys, uPrint, and FDM are registered trademarks of Stratasys, Inc. Designjet 3D and HP are trademarks of Hewlett-Packard.

SOURCE: Stratasys, Inc.

 

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3D Printing; General-Types-Type-Comparison-Materials

3D printing is a complex subject, and so we've compiled information on the topic from various sources. 

Often referred to as 3D printing, these processes are also referred to by other names such as rapid prototyping, direct digital manufacturing, or any of the process names. All 3D printing works on the concept of building up layers of material on top of each other to produce a finished part. During the process, any part of the model that overhangs must be supported - each process handles this differently which can have implications for the final product. Some processes allow for multiple parts to be nested together / built at once with only a slight increase in build time – this is better for higher volume orders.

Every process has its strengths and weaknesses - to best utilize the technology, you'll need to understand how each can be used to its full advantage

FDM – Fused Deposition Modeling

This is currently the most widespread form of 3D printing. All new machines are built by Stratasys under the trade names Dimension or Fortus. It builds each layer by extruding a thin filament of nearly-melted thermoplastic onto a build surface. It builds in a criss-cross fashion, so that each layer's “grain” is perpendicular – which makes the part stronger. It's support material comes in break-away and soluble forms – the latter allows for much more complicated geometries by allowing water to wash away support.

Strengths:

• plastics used are very durable
• a wide variety of materials are available
• soluble support technology allows for intricate geometry, including simple moving parts
• materials are cheap

 

Weaknesses:

• Untreated surfaces have a rough finish
• Strength along the Z-axis direction is far less than in X or Y (because of layer adhesion)
• Slower build-times with multiple parts

 

SLA – Stereolithography Apparatus

This was the original form of 3D printing. Currently, all systems are built by 3D Systems. The process forms each layer by scanning a UV laser over a build surface covered in a special resin that cures when exposed to UV light. The plate lowers into a vat to re-coat the surface for each layer. Support material is the resin itself.

Strengths:

• Accuracy
• Good surface quality
• Wide variety of materials

 

Weaknesses:

• Resins
• Long post-processing times (due to removing support material)
• Resins are toxic & unsafe for an office environment

 

PolyJet / ProJet

PolyJet is produced by Objet Geometries, and ProJet is produced by 3D Systems. This form of 3D printing lives up to the name “printing”. These machines work similarly to inkjet printers, but instead of using ink they use resin. The resin is jetted onto the surface and then cured by a passing light – similarly to the SLA curing. The support material isn't quite soluble, but is washed away by a jet of water.

Objet's Connex systems can print in multiple materials at the same time. This allows models to have transparent features with opaque internal parts. Also, using their “Digital Materials” technology, you can even intermix the materials with a variable ratio to allow parts with multiple materials properties in one build.

Strengths

• Great Accuracy
• High Resolution / Feature Detail
• High complexity parts
• Moving parts are possible
• Ability to print in multiple-materials

 

Weaknesses

• Expensive
• Support can be difficult to remove in some circumstances – limiting some geometries

 

Z-Corp

Another form of 3D printing using inkjet technology is known by the company's name: Z Corp. These machines create each layer by using an inkjet head to deposit a binder onto a bed of compacted powder. Powder is layered and cured in succession until a part is formed. After each build, the loose powder is removed leaving only the part remaining. The fresh part is then coated in elastomer which gives the parts added rigidity. Some machines have the ability to print parts in full color.

Strengths

• Fast part production
• The only full color parts process

 

Weaknesses

• Fragile parts – even when coated
• Lowest surface quality than other “jet” processes

ThermoJet / Solidscape

These machines print in wax in a similar method to the ProJet / PolyJet processes. They build up layers of wax by printing each layer on top of the last. Solidscape machines are used to print in wax that is later used as a lost-wax pattern in metal casting – used by jewelers to create rings. ThermoJets are generally used to produce purely aesthetic parts.

Strengths

• Accurate
• High detail
• Great surface quality
• Cheap

 

Weaknesses

• Very fragile wax parts
• Limited Materials

 

SLS/SLM/DMLS – Selective Laser Sintering/Melting & Direct Metal Laser Sintering

In this process, a laser is scanned across the top of a compacted powder surface. The laser is strong enough that it sinters / melts the materials together.

Strengths

• Wide range of materials
• Durable parts
• Accurate
• Good at bulk jobs (because each layer can be sintered quickly)

 

Weaknesses

• Expensive (machine purchase cost)
• Mediocre surface quality
• Large flat parts tend to warp

 

ProMetal - Direct Metal Printing

This technique is named after the trade name of the company that builds it: ProMetal. The process is similar to Z Corp where an inkjet head deposits binder onto a powder surface. The difference is that the powder is stainless steel and must be sintered in an oven. Later, the part is “infiltrated” to full density by heating the part in the furnace over bronze. This produces a hybrid SS / bronze material – gold is also possible.

Strengths

• Cheapest metal printing
• Bulk part printing
• Ability to print very large parts

Weaknesses

• Lower accuracy
• Limited
• Casting quality surface finish

ProMetal RCT – Rapid Casting Technology

This is similar to the other ProMetal method, however instead this one produces sand molds for metal casting. The end result after casting is a part of identical quality as traditional green sand casting, without the need to produce patterns – this cuts time and enables novel geometries.

Strengths

• Fastest metal castings
• No limited on material to be cast

 

Weaknesses

• Expensive (machines & prints)

 

DLP (EnvisionTec)

This technique is exclusive to EnvisionTec and is similar to SLA in that it uses a vat of light-curable resin. Instead of using a laser, it uses a DLP chip and a UV light source to cure each layer in one step (no XY scanning). This makes it five times faster than SLA.

Strengths

• Accurate
• High Resolution / Feature Detail
• Fast
• Casting friendly materials

 

Weaknesses

• Expensive (machine purchase cost)
• Accuracy fall-off (more accurate in the center than edges)

 

LOM – Layered Object Manufacturing

This process uses layered sheets of material (usually paper or plastic) that are cut out by laser or blade and adhered together. The latest version of this process is the Mcor Matrix which uses A4 printer paper and PVA glue to make prototypes.

Strengths

• Very cheap & available materials (paper & glue)
• Thin layer thickness
• Greenest 3D printing technology

 

Weaknesses

• Limited material selection
• Lower part strength

 

Other processes:

V-Flash

This system was released by 3D Systems to reach the low-cost / desktop market. Each layer is applied using a resin coated plastic sheet which applies materials.

Strengths

• Inexpensive
• Good accuracy
• Good resolution

 

Weaknesses

• Supports made of build material – high post-processing time
• Limited part size

 

Huntsman Digitalis

This system is currently only in prototype form and was debuted at the 2009 RAPID Show. It uses a novel Micro Light Switch technology to expose a vat of resin to a UV curing light.

Strengths

• Fast
• Accurate
• High Resolution
• Large build area

 

Weaknesses

• Limited Materials
• Probably will be expensive

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FDM (Fused Deposition Modeling)

Fused Deposition Modeling (FDM) is a solid-based rapid prototyping method that extrudes material, layer-by-layer, to build a model. The system consists of a build platform, extrusion nozzle, and control system. 

The build material, production quality thermoplastics, is melted and then extruded through a specially designed head onto a platform to create a two-dimensional cross section of the model. The cross section quickly solidifies, and the platform descends where the next layer is extruded upon the previous layer. This continues until the model is complete, where it is then removed from the build chamber and cleaned for shipping. 

Fused deposition modeling, which is often referred to by its initials FDM, is a type of additive fabrication or (sometimes called rapid prototyping / rapid manufacturing (RP or RM)) technology commonly used within engineering design. The technology was developed by S. Scott Crump in the late 1980s and was commercialized in 1990. The FDM technology is marketed commercially by Stratasys, which also holds a trademark on the term.

Like most other additive fabrication processes (such as 3D printing and stereolithography) FDM works on an "additive" principle by laying down material in layers. A plastic filament or metal wire is unwound from a coil and supplies material to an extrusion nozzle which can turn on and off the flow. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism, directly controlled by a computer-aided design software package. The model or part is produced by extruding small beads of thermoplastic material to form layers as the material hardens immediately after extrusion from the nozzle.

Several materials are available with different trade-offs between strength and temperature properties. As well as acrylonitrile butadiene styrene (ABS) polymer, the FDM technology can also be used with polycarbonates, polycaprolactone, polyphenylsulfones and waxes. A "water-soluble" material can be used for making temporary supports while manufacturing is in progress. Marketed under the name WaterWorks by Stratasys, this soluble support material is quickly dissolved with specialized mechanical agitation equipment utilizing a precisely heated sodium hydroxide solution.

Commercial applications
Most available commercial printers using FDM technology utilize positioning systems employing either stepper motor or servo motors to move the extrusion head.

In 2006, FDM was the best-selling rapid prototyping technology.

FDM systems include two different product lines. The "high-end" FDM systems include the FDM 900mc, FDM 400mc, FDM 360mc and FDM 200mc. These systems are the highest performance FDM systems capabale of producing parts from the largest range of thermoplastic materials, feature detail, surface finish, accuracy. FDM uses production-grade thermoplastics, such as ABS, ABSi, polyphenylsulfone (PPSF) and polycarbonate (PC), including PC-ABS. Because of the material properties, FDM parts typically withstand functional testing and have high heat resistance. Some companies have sterilized PPSF for medical applications, however material manufacturer Stratasys does not advertise that PPSF is sterilizable.

Stratasys also markets a line of 3D Printers that print 3D models using the same core FDM technology. Called Dimension systems, these 3D Printers don't have the same performance or material options as a "high-end" FDM system, but are much less expensive.

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CAD file to part in just three steps.

All Stratasys FDM systems produce thermoplastic parts in just three steps, unlike some competitive additive fabrication processes that have up to 16 steps. Just load your file, machine produces part and remove the support material.

1. Pre-Process - Load the part’s STL file (CAD data) in Insight file processing software.
2. Manufacture Parts - System builds part in thermoplastic material one layer at a time on precise paths.
3. Remove Supports - Remove temporary support structures in a hands-free soluble support tank.

While competitors simulate thermoplastics using powders and resins, models and parts produced using FDM technology are produced from real thermoplastic materials and as a result are much more versatile. Parts can be used as prototypes, concept models, functional parts to test form and fit, manufacturing tools, and end-use production parts.

Stratasys: FDM (Fused Deposition Modeling Technology)

FDM(Fused Deposit Modeling)

Fused Deposition Modeling (FDM) is a solid-based rapid prototyping method that extrudes material, layer-by-layer, to build a model. The system consists of a build platform, extrusion nozzle, and control system.

-The build material, production quality thermoplastics, is melted and then extruded through a specially designed head onto a platform to create a two-dimensional cross section of the model.

- The cross section quickly solidifies, and the platform descends where the next layer is extruded upon the previous layer. This continues until the model is complete, where it is then removed from the build chamber and cleaned for shipping.

3D Printing, Rapid Prototyping

Dimension Printing

So Many Applications, So Many Advantages

Lead time: Normally 1-3 business days depending on the capacity of the printers when we receive payment. Local customers are welcomed to pick up models from our facility

DDM Layer thickness: Horizontal build layers can be built in three options fine (.007"), standard (.010"), and rough draft (.013")

Minimum Wall Thickness: .020"

Dimensional Tolerances: ABS models maintain tolerances of +/- .005" for the first inch, and +/- 0.002" for each additional inch. In the z height (vertical), standard tolerances of +/- 0.010" for the first inch, +/- 0.002” on every inch thereafter.

Build size: for a single piece is 8" x 8" x 12". Models that are larger than the build envelope can be divided, printed as separate pieces, & assembled.

= Fused Deposition Modeling (FDM) is a solid-based rapid prototyping method that extrudes material, layer-by-layer.

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