• Just like an "Extrusion" process where, for example, toothpaste is pushed through the tube opening and then it is applied onto the toothbrush... similar to that, a filament of solid thermoplastic material is fed through a heated extrusion nozzle in the form of beads or a stream, melting it during this process. The nozzle deposits the material on a build platform along a predetermined path, where the material cools and solidifies to form a solid object layer by layer.

• Once the first layer is complete, the build platform moves downwards, and the nozzle proceeds to lay down another layer. This process of printing cross-sections is repeated, building layer-upon-layer until the object is fully formed.

• Depending on the geometry of the object, 3D model processor software of the printer analyses different curved or overhanging features & adds necessary support structures while printing.

• This overall process is called as "Fused Deposition Modelling" (FDM).  It is sometimes also referred as "Fused Filament Fabrication" (FFF).

• Recently, this process has been expanded to print directly from pellets to avoid conversion to filament, which is called as "Fused Particle Fabrication" (FPF) or "Fused Granular Fabrication" (FGF), which now has the potential to use more recycled materials.

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• Materials: Thermoplastic Filament (PLA, ABS, PET, PETG, TPU)

• Dimensional Accuracy: ± 0.5%  

• Common Applications: Electrical housings, Form & Fit testing, Jigs & Fixtures, Casting Patterns etc

• Strengths: Best surface finish, Full colour and multi-material 

• Weaknesses: Brittle, Not sustainable for mechanical parts, Higher cost than SLA / DLP for visual purposes.

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