FDM 3D printing (fused deposition modeling) builds parts from real thermoplastics, from everyday PLA and PETG to carbon fiber nylons and aerospace-grade ULTEM. It is a cost-effective way to make durable prototypes, fixtures, and end-use parts, and it can build very large parts. Our shop is in Coopersville, Michigan, just west of Grand Rapids, and we ship parts nationwide.
How FDM 3D Printing Works
FDM was invented by S. Scott Crump, co-founder of Stratasys, in 1988. The generic name for the process is fused filament fabrication (FFF).
- A spool of thermoplastic filament feeds into a heated print head.
- The print head melts the filament and deposits it as a thin bead, tracing the outline and fill of one layer of the part.
- The build platform lowers one layer at a time and the process repeats until the part is complete.
- Support material is removed, and the part can be finished by sanding, painting, or vapor smoothing.
When to Choose FDM 3D Printing
FDM is the right fit when you need a durable part in a real engineering thermoplastic, especially when the part is large or the budget is tight:
- Jigs, fixtures, and manufacturing aids
- Large prototypes and housings, up to 36″ × 24″ × 36″ in one piece
- Strong, stiff parts in carbon fiber reinforced materials
- Static-dissipative fixtures for electronics assembly
- Flame retardant and high-temperature parts for aerospace and transportation
- Outdoor and UV-exposed parts
- Flexible TPU parts such as bumpers, grips, and strain reliefs
- Low-cost concept models and fit checks
FDM or MJF? FDM covers the widest range of engineering plastics and the largest part sizes, and it is often the most economical choice for big or one-off parts. For small to medium nylon parts, fine detail, or larger quantities, MJF usually gives a better surface and lower cost per part. Not sure? Send us the part and we will recommend a process.
FDM 3D Printing Capabilities
| Maximum part size | Up to 36″ × 24″ × 36″ in one piece; larger parts can be printed in sections and bonded |
| Layer thickness | 0.007″ to 0.013″, depending on material and part |
| Accuracy | ±0.035″ for the first 5″, ±0.010″ per inch thereafter (see our part accuracy page) |
| Surface finish | Visible layer lines; can be sanded, painted, or vapor smoothed |
| Materials | 17 thermoplastics, from PLA and PETG to carbon fiber composites, ULTEM, and flexible TPU |
Accuracy depends on part size, geometry, and material. Send us your CAD file and we will give you a realistic estimate for your part.
FDM 3D Printing Materials
Each material has its own page with full mechanical properties, data sheets, and part photos.
Everyday and prototyping
| Material | Best for |
|---|---|
| PLA | Low-cost concept models, fit checks, and visual prototypes |
| PETG | Tough, economical functional prototypes with good chemical and moisture resistance |
| ASA | Outdoor and UV-exposed parts that need to hold their color and strength |
ABS and polycarbonate
| Material | Best for |
|---|---|
| ABS-M30 | Strong, tough general-purpose prototypes and fixtures |
| ABS M100 | Durable, versatile parts in several colors |
| PC-ABS | Impact-resistant parts with good heat resistance |
| Polycarbonate (PC) | Strong, heat-resistant functional parts and tooling |
| PC-ISO | Biocompatible polycarbonate for medical and food-handling applications |
Specialty
| Material | Best for |
|---|---|
| ABS-ESD7 | Static-dissipative fixtures and parts for electronics assembly |
| Firewire Flame Retardant ABS | UL 94 V-0 rated enclosures and covers |
Carbon fiber and high performance
| Material | Best for |
|---|---|
| ASA+CF | Stiff, UV-stable carbon fiber parts with good heat resistance |
| Obsidian Nylon 6+CF | High-strength carbon fiber nylon for fixtures, tooling, and end-use parts |
| PPA-CF | High-temperature carbon fiber parts with exceptional stiffness |
| PPS-CF | Flame retardant carbon fiber parts with excellent heat and chemical resistance |
Aerospace grade
| Material | Best for |
|---|---|
| ULTEM 1010 | Very high heat and chemical resistance for tooling and demanding parts |
| ULTEM 9085 | Flame, smoke, and toxicity rated parts for aerospace and transportation |
Flexible
| Material | Best for |
|---|---|
| TPU 85A to 68D | Flexible, durable, abrasion-resistant rubber-like parts in a range of hardnesses and colors |
See the chemical compatibility data for FDM materials, or compare FDM with our other processes on the machine and material comparison guide.
Finishing Options for FDM Parts
FDM parts show visible layer lines straight off the printer. Depending on the material, we can sand and paint, vapor smooth, or Cerakote parts, and install heat-set inserts. See all finishing and post-processing options.
Designing Parts for FDM
Our engineering team at DeWys Engineering designs parts for FDM regularly. If your part isn’t ready to print yet, our design for additive manufacturing services can help, from design review to full CAD design.
If you would rather design the part yourself, we strongly recommend starting with our FDM Part Design Guide. Our engineers built it from years of FDM projects as a place to keep the lessons we have learned, and we publish it so anyone designing for FDM can benefit. It covers wall thickness, orientation, supports, and how to get the strongest part.
A few things FDM handles well:
- Sharp internal corners and no draft required
- Brass threaded inserts heat-set into the part
- Printed threads above ½″
- Serial numbers and text printed into each part
- Honeycomb interiors to save weight and material
- Large parts printed in sections and bonded
FDM Part Examples
FDM 3D Printing FAQ
How strong are FDM parts?
FDM parts are made from real thermoplastics, so they are strong and durable. They are strongest along the layers and weaker between layers, so we orient parts to put the strength where it is needed. Carbon fiber materials such as Obsidian Nylon 6+CF and PPA-CF add a lot of stiffness.
How big can FDM parts be?
Up to 36″ × 24″ × 36″ in one piece. Larger parts can be printed in sections and bonded.
Is FDM or MJF better for my part?
FDM is usually best for large parts, one-offs, and when you need a specific engineering material such as ULTEM or carbon fiber nylon. MJF is usually best for small to medium nylon parts with fine detail, and for larger quantities.
How fast can I get FDM parts?
Small parts that fit in the palm of your hand can often be ready in about 2 days. For anything larger, lead time depends on the size and geometry of the part and the material. FDM is a slower process, and a large part can print continuously for several days. Send us your CAD file and we will give you a lead time for your project.
Can FDM print flexible parts?
Yes. We offer TPU in hardnesses from 85A to 68D for bumpers, grips, strain reliefs, and other rubber-like parts.
ISO 9001:2015 Certified Quality
Our quality management system is certified to ISO 9001:2015 and covers engineering, additive manufacturing, post-processing, and inspection, so customer requirements are handled consistently from quote to delivery. Learn more about our ISO 9001:2015 certification.