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FDM 3D Printing Service
Access an FDM 3D printing facility for prototyping
or batch production. Click on get a quote, upload
a file and accept the quote to start FDM 3D printing in Pune.
FDM is a fast, cheap and fairly efficient way of making 3D printed parts. In FDM, plastic filament is squeezed through hotend, melting it and then deposited in pre-defined path layers by layer to create a form. We have a large facility for FDM 3D printing service in Pune, ready for prototyping or batch production. With 6+ material support and multiple post-processing options, receive your functional 3D printed parts within days.
FDM Capabilities
| Maximum Build Size | Maximum Hotend Temperature | Maximum Build Chamber Temperature | Dimensional Accuracy | Average Lead Time |
|---|---|---|---|---|
|
400mm X 400mm X 500mm |
390 °C* |
150 °C* |
± 0.5% with a lower limit of ± 0.2 mm |
2 Business days |
*For build size of 220 x 220 x 250mm.
FDM Materials
Material Name
Subtype
Maximum Service Temperature
Ultimate Tensile Strength
Elongation at break
PLA
Standard
52 °C
65 MPA
7.7 %
7.7%
ABS
Standard
98 °C
40 MPA
10.3 %
10.3%
ABS M30
99 °C
46 MPA
10.8 %
10.8%
ASA
Standard
95 °C
55 MPA
13.2 %
13.2%
Flexible
TPE
55 °C
5 MPA
>500 %
TPU
60 °C
8 MPA
>350 %
PETG
Standard
73 °C
53 MPA
14.4 °C
14.4%
Nylon
Standard
95 °C
46 MPA
14.8 °C
14.8%
PP
Standard
100 °C
32 MPA
> 54 %
Carbon Fiber Filled
CAF PLA
53 °C
48 MPA
6.3 %
6.3%
CAF ABS
100 °C
38 MPA
9.6 %
9.6%
The standard test methods are used to determine mechanical properties
- ASTM D638 – Standard Test Method for Tensile Properties of Plastics
- ISO 527-1:2012 – Determination of tensile properties. General principles
FDM Post Processing Options
Removal of the support structure
Removal of the support structure is the most basic form of post-processing. Support removal is an easy process unless there are supports in hard-to-reach places. There are two types of supports, soluble or insoluble. Soluble supports are easy to remove and provide a better finish on the supported member.
We provide both soluble and insoluble support options to our customers and support removal as a standard post-processing service.
Sanding
Sanding is the most common method of post-processing. FDM 3D prints can have a slightly rough surface, and sanding is the easiest way to smooth it. For large prints, we provide sanding as an additional post-processing service. The part tolerance can vary up to 500 microns, thus it is suggested to avoid sanding of tolerance sensitive 3D printed parts.
Priming and painting
Priming and painting post-processing methods are for enhancing the look, adding colour, as well as the finish of a part. Priming and painting are not recommended for tolerance sensitive 3D printed parts. We have a team of skilled creators for professional priming and painting services. Just upload the 3D model and list the colour of your choice to receive an instant quotation.
Cold welding and vapour smoothing
Cold welding is a standard 3D printing service for large ABS 3D prints or 3D printing complex parts with a minimal support structure.
Smoothing is a popular post-processing technique for ABS prints. Acetone is used to melt the upper layer of ABS print and therefore smooth away the layer lines visible on a part’s surface. This makes 3D printed parts look smooth and shiny but dimensional accuracy is compromised. We provide vapour smoothing as an additional post-processing service.
Epoxy Coating
Epoxy coating of 3D printed model is carried for improving strength and adding a durable protective layer. But this post-processing method seals all porous parts of the print. This is not a finishing technique so the layer line still may be visible. We provide epoxy coating as an optional post-processing service for FDM 3D printing in Pune facility.
FDM Design Guidelines
-
Shrinkage
This shrinkage is a direct result of the transition from a semi-solid to a solid-state during the FDM process. Various factors are contributing to the shrinkage of 3D printed parts such as type of material environmental temperature. On average the shrinkage rate of PLA is somewhere between 2.0%-2.5%, ABS between 8%-9% and that of nylon is less than 1.7%. We take care of shrinkage through slicer settings and machine calibration, so all the 3D printed parts by DigiPro 3D are within the tolerance limit.
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Minimum Wall Thickness
Wall thickness is limited by the nozzle diameter and features thinner than 90% of the nozzle size usually does not print successfully. Features with only one layer of the wall are weak and inaccurate. For supporting structures, walls need to be at least 1.2 - 1.5 mm thick for best results by allowing the filament to fill between layers.
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Hole Orientation
Holes on an FDM part are generally undersized. Orientation of holes is very important and they tend to be more accurate when printed parallel to the build plate. DigiPro 3D recommends minimum diameter of holes for FDM be designed greater than 1mm to retain a circular shape. For maintaining tight tolerances, holes will be drilled or reamed to ensure the diameter is as designed.
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Threads
For fine threads in FDM, it is more appropriate to incorporate a heat-set insert into your design, which is added after your part has been 3D printed. It is possible to 3D print functional threads if they are large and coarse. When using modelled thread, Creating an ACME thread design with rounded roots and crests has been found to work well. Also for better printability in FDM, the pitch of the thread should be more than 1.5mm.
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Text and small details
Texts and small details are very hard to 3D print as many small features do not register during the slicing process. It is recommended to use a font with consistent text width. Minimum suggested text width must be 1.2mm- 1.5mm and protrusion 1mm to be legible and avoid unexpected errors.
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Overhangs
When the printed layer of material is only partially supported by the previous layer, it's considered an overhang. The maximum inclination for an overhang is 450, i.e overhang is successfully printed without supports up to 450. For inclination greater than that a support structure is required to avoid print failure.
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Fillets and Ribs
If there are sharp corners or edges in the part stress concentration at these regions is high so are the chance of failure under load. Fillets and ribs can be used to decrease stress concentration and increase strength thus chance of failure is reduced. If fillet or rib is applied to a small overhang the support structure requirement can be eliminated. For FDM 3D printed part, it is advised to keep a fillet radius greater than 1 mm.
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Orientation
FDM 3D printed parts are anisotropic due to the nature of the process. Orientation has an enormous impact on anisotropic behaviour and appearance. The extruded part has more tensile strength along the XY plane and lower strength in the z-direction. Critical features such as circle, steep curvature print better when printed parallel to the XY plane. Designing a part so that weak and concentric features are placed in the parallel direction to the XY plane will help determine the best orientation for a part. Overhanging features along z-direction requires support during 3D printing which increases build time and material usage. A designer should ensure to minimize such overhangs in a model.
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Assemblies
DigiPro 3D can produce fully assembled 3D printed parts provided proper clearance is given between mating assembly parts. The X/Y clearance should be greater than the default extrusion width and Z clearance greater than slice thickness.
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Post-processing
Parts manufactured by the FDM 3D printing method can be subjected to various post-processing including machining operations such as drilling and tapping, turning, and milling. DigiPro 3D provides services for surface finishing like smoothing, burnishing, sealing and plating.
General FDM Tolerances
FDM tolerances for 0.1mm slice thickness are given below, these are subjected to change with change in print parameters.
- +/- 0.004 or +/- 0.002 per mm in the XY direction, whichever is greater.
- +/- 0.010 or +/- 0.002 per mm in the Z-direction, whichever is greater.
- DigiPro 3D chooses part orientation to optimize part quality and appearance unless otherwise specified.
- The minimum resolvable feature size, including positive text features, is at least 0.9mm (0.12mm or greater is safest).
Applications of FDM
- Rapid prototyping
- Low volume production
- Personalized Prosthetics
- Pre-surgical models
- Architectural models
- Custom tooling: Jigs and fixtures
- Spare parts
Benefits of FDM
With calculated compensation for shrinkage and post-processing method FDM printed parts are accurate and within process tolerance. Complex geometries and cavities that would otherwise be problematic become practical with FDM technology.
FDM technology supports production-grade thermoplastics that are mechanically and environmentally stable. For these thermoplastics range of post-processing methods are available. At DigiPro 3D, we suggest the correct combination to deliver a market-ready product.
The FDM process uses engineering-grade thermoplastic filament that is easily available and affordable. FDM machines have a modest size means parts don’t have to be manufactured in a large facility, helping to lower the expense of producing small components. DigiPro 3D provides cost-effective services for FDM in Pune facility.