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Fused deposition modeling (FDM) 3D printing makes a part by feeding thermoplastic filament through a heated nozzle and depositing it in a sequence of planned paths. The strands cool and bond layer by layer. The printer follows paths generated from a digital model; depending on the part’s shape, it may also print temporary supports.
What FDM printing does
FDM is a form of material extrusion: instead of removing material from a block, the printer adds softened plastic where the part needs it. HP describes FDM as a process that unwinds plastic filament from a spool and supplies it to a nozzle. The broader filament-extrusion family is also called fused filament fabrication (FFF); HP notes that FDM is a trademarked term and FFF is an untrademarked equivalent.
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The finished object is built from many deposited strands. The machine controls where each strand goes, while cooling and bonding turn those separate passes into a single part.
How the process turns a model into a part
1. The model is sliced into paths
The workflow starts with a digital 3D model, commonly created in CAD. Build-preparation software slices the model into layers and generates the toolpaths the printer will follow. Stratasys describes those paths as being defined from CAD data, with slicing as a preprocessing step. The printer uses this plan to determine where to deposit material as the build progresses.
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2. Filament is fed toward the hot end
A spool holds a continuous length of thermoplastic filament. A feed mechanism advances it toward the printer’s hot end, which contains the heated nozzle. The filament is the printer’s feedstock: the machine draws on it as it builds the part.
3. The nozzle softens and deposits the plastic
The hot end heats the filament until it can flow through the nozzle. The printer moves the nozzle along the programmed path while feeding material, laying down a continuous strand. The result depends on coordinated material feed and motion; if either does not match the intended path, the deposited strand will not land as planned.
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- Supported Filament: Ideal: PLA, PETG, TPU, PVA, PET ABS, ASA; Capable : PA, PC; Not Recommended: Carbon/Glass Fiber Reinforced Polymer.
4. Strands cool and layers build upward
After deposition, the thermoplastic cools and solidifies. The printer positions the next path above the previous one, and new material fuses with the layer beneath it. Repeating this sequence produces the part’s height and shape one layer at a time. HP, Stratasys and the U.S. Department of Energy describe this basic pattern of depositing material and building successive layers.
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5. Supports are added only when the geometry calls for them
Some shapes include sections that cannot be built directly without temporary support. A capable printer may deposit a secondary material for those sections; some systems use a dissolvable support material. This is an optional process choice, not a feature required for every FDM machine or print. The need depends on the part’s geometry and the printer’s capabilities.
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- Ultra-Fast 12X Printing Speed: The AD5X features a Core XY structure with speeds up to 600mm/s and acceleration of 20,000mm/s². Its stable design boosts both efficiency and print quality, making it ideal for rapid prototyping and batch production.
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- Versatile Nozzle Options: The AD5X supports four nozzle sizes (0.25mm to 0.8mm) for full creative control. The 0.4mm nozzle comes pre-installed for versatile, everyday printing. For specialized tasks, optionally upgrade to the ultra-fine 0.25mm nozzle for miniature details, or to the 0.6mm/0.8mm nozzles to slash print time on large, sturdy models.
What determines the material and support choices
Match filament to the printer
FDM systems can use different thermoplastics, including ABS, nylon and polycarbonate, but a material name alone does not establish that it will work in a particular printer. Printer design and material compatibility affect which filament is appropriate. Operating temperatures also vary with the printer and material, so there is no single universal FDM temperature or setting to apply to every machine. Check the printer manufacturer’s compatibility guidance before choosing filament or settings.
Let geometry guide support use
A part that can be built directly from the layers below may not need support. Features that extend beyond what is already built can require temporary material beneath them, depending on the design and print orientation. A second nozzle and soluble support material can make some complex builds easier, but that capability is specific to supported printer systems.
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What to keep in mind
- FDM adds thermoplastic rather than cutting a shape out of solid stock.
- The printer follows paths generated by slicing a digital model.
- Deposited strands cool, solidify and fuse with material beneath them as the part grows.
- Filament compatibility and operating conditions vary by printer and material; do not assume one setting works for all FDM systems.
- Supports are used when a shape needs them, and printing a second dissolvable material requires a compatible system.
Sources
- HP: Introduction to 3D printing processes
- Stratasys: How it works: FDM 3D printing with FDM
- U.S. Department of Energy: How 3D Printers Work
- Royal Society of Chemistry: An Introduction to 3D Printing
- American Chemical Society: An Introductory Guide to 3D Printing
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