Chloe Zhang
Plastic extrusion 3D printing, also known as Fused Deposition Modeling (FDM) or Material Extrusion, is a process that uses plastic filament to create objects layer by layer. The plastic filament is fed through a heated printer extruder head, which deposits the molten material onto a 3D printing platform. This process is controlled by a computer, which moves the extruder head along at least three axes. Plastic extrusion 3D printing is a versatile technique that can be used to create a wide range of objects, from aerospace components to jewellery.
| Characteristics | Values |
|---|---|
| Name | Fused Deposition Modeling (FDM) or Material Extrusion |
| Process | Uses spools of plastic or metal filament that are extruded through a heated nozzle layer by layer to create a 3D part |
| Raw Materials | Plastic pellets made of thermoplastic materials like PLA, ABS, PETG, etc. |
| Sustainability | Embracing recycling and sustainability by transforming plastic waste and failed prints into usable filaments |
| Applications | Used in aerospace, automotive, and medical sectors |
| Other Materials | Can also extrude paste-like materials such as ceramics, concrete, and chocolate |
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What You'll Learn
Fused Deposition Modeling (FDM)
To operate an FDM machine, a spool of thermoplastic filament is loaded into the printer. Once the nozzle reaches the desired temperature, the printer feeds the filament through an extrusion head and nozzle. This extrusion head is attached to a three-axis system that allows it to move across the X, Y, and Z axes. The printer extrudes melted material in thin strands and deposits them layer by layer, following a path determined by the design. The material then cools and solidifies, with fans sometimes attached to the extrusion head to accelerate this process. This process repeats until the part is complete.
FDM technology is versatile, user-friendly, and offers a wide range of materials, making it a popular choice for industries seeking cost-effective alternatives to traditional manufacturing. It is particularly useful for creating parts with complex geometries and internal cavities. FDM printers vary in size and capability, from small desktop printers to large-capacity industrial printers.
FDM's typical layer height ranges from 50 to 400 microns. Shorter layers result in smoother parts and better capture of curved geometries, while taller layers allow for faster and more economical printing. Secure adhesion between deposited layers is critical in FDM to ensure strong bonding. FDM parts always have a wavy surface due to the deformation of the molten material as it presses against the previously printed layer.
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Plastic pellets as raw materials
Plastic pellets, also known as nurdles, are small meltable balls that are used as raw materials in the manufacturing of plastic products. They are used in traditional manufacturing methods such as injection moulding and are also compatible with 3D printing processes. Leveraging pellets in 3D printing provides the advantage of using qualified materials seamlessly across different manufacturing technologies.
The process of 3D printing with plastic pellets is known as Fused Granulate Fabrication (FGF) or Pellet 3D Printing. It involves feeding and extruding plastic pellets through a nozzle using a high-speed, precision motion system. FGF can achieve print speeds up to 200 times faster than fused filament fabrication (FFF).
One of the key benefits of using plastic pellets in 3D printing is the ability to create tailor-made blends through the mixing of different plastics. This versatility is particularly valuable in the healthcare sector for crafting biocompatible materials, customized prosthetics, and implants. Pellets are also used in the automotive sector for developing customized parts and in the design sector for creating larger furniture and decorative items.
Additionally, pellets can be produced from recycled materials, promoting sustainability and the circular economy. They offer efficiency in material prototyping, as the same raw material can be used for both 3D printing and injection moulding without requiring additional certification stages. This saves manufacturers time and resources.
However, using plastic pellets in 3D printing requires a deeper understanding of the processability of each material and the optimal settings to achieve high-quality results. Factors such as pellet size, geometry, moisture content, and heating zones need to be carefully controlled to ensure a consistent and safe flow of material during the extrusion process.
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Continuous filament of thermoplastic
3D printing, also known as additive manufacturing, uses a variety of techniques to build parts layer by layer. One such technique is material extrusion, which uses plastic filaments to create prototypes. Fused filament fabrication (FFF), also known as fused deposition modelling (FDM), is a type of material extrusion 3D printing that uses a continuous filament of thermoplastic material.
FFF is a process where a continuous filament of thermoplastic is fed from a large spool through a moving, heated printer extruder head, which deposits the filament onto the growing work. The print head is controlled by a computer and usually moves in two dimensions to deposit one horizontal plane or layer at a time. Once a layer is complete, the work or the print head is moved vertically by a small amount to begin a new layer. The speed of the extruder head can be controlled to stop and start deposition and form an interrupted plane without stringing or dribbling between sections.
The thermoplastic filament is introduced into the printer by mechanical pressure from rollers, which feed it into the liquefier (or hotend), where it melts and is then extruded. The flow geometry of the extruder, heating method, and the melt flow behaviour of a non-Newtonian fluid are key considerations in this process. The rollers are the only drive mechanism in the material delivery system, so the filament is under tensile stress upstream of the roller and under compression downstream.
The thermoplastic filament used in FFF comes in a range of diameters, most commonly 1.75 mm and 2.85 mm. The diameter of the filament is defined by the process that takes place after the plastic has been heated, rather than the diameter of the extruder nozzle. A different force and speed are applied to the filament as it is pulled out of the extruder to define its width.
The colour of a given thermoplastic material can also affect the strength of the printed object. Pigments or other additives are added to the material before it is melted to create coloured filaments or filaments with special properties, such as increased strength or magnetic properties.
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Composite Filament Fabrication (CFF)
Plastic extrusion in 3D printing is called Fused Deposition Modeling (FDM). This process uses spools of plastic or metal filament that are extruded through a heated nozzle layer by layer to create a 3D object.
The CFF process involves the deposition of continuous carbon fiber filaments within a thermoplastic material matrix. The strength and lightweight properties of carbon are combined with the versatility of thermoplastic materials, resulting in robust and lightweight parts. The printing process starts by feeding continuous carbon fiber filaments together with a compatible thermoplastic material into the print nozzle, where they are fused and deposited layer by layer on the build platform, creating a solid and strong structure.
CFF printers use two nozzles. One nozzle operates like a typical extrusion process, laying down a plastic filament that forms the outer shell and internal matrix of the part. The second nozzle deposits a continuous strand of composite fiber (made with carbon, fiberglass, or Kevlar) on every layer. This continuous strand of composite fibers inside the 3D-printed parts adds strength comparable to metal objects. The strategy used to lay down the layers can also affect the part's strength. For example, Markforged recommends the Isotropic Fiber fill pattern, where layers are unidirectional, similar to traditional laminated composites.
Overall, CFF is a revolutionary 3D printing technology that offers enhanced strength, durability, and lightweight properties by combining continuous carbon fiber filaments with thermoplastic materials. This technology is well-suited for applications requiring high strength-to-weight ratios and has the potential to transform various industries.
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Melt extrusion
To begin the melt extrusion process, a user creates a 3D model using specialized software, saving it as an STL file. This file is then sent to the 3D printer's interfacing software, which slices the model into thin layers and determines how each layer will be printed. The model is then fed to the 3D printer, which heats the plastic or metal filament and extrudes it through a nozzle, building the object layer by layer.
One of the critical aspects of melt extrusion is the use of a melt pump, which improves the consistency and precision of the filament geometry. By reducing the pulsation of the melt, the melt pump enhances the overall stability and accuracy of the printing process. This technology has been of particular interest to the pharmaceutical industry, where it is used to create drug tablets with specific release characteristics and kinetics.
Additionally, melt extrusion has been combined with powder-based materials, leading to the development of powder melt extrusion (PME) 3D printers. These printers can print parts directly from powder-based materials, bypassing the need for filament. This innovation further expands the capabilities of 3D printing, making it more accessible for novel material feedstock.
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Frequently asked questions
Plastic extrusion 3D printing is a process that uses spools of plastic filament fed through a heated nozzle layer by layer to create a 3D object.
The process of plastic extrusion 3D printing involves creating a model using 3D software and saving it as an STL file. The file is then sent to the 3D printer's interfacing software, which slices the model into sections and determines how each layer will be printed. The model is then sent to the 3D printer, which extrudes the plastic filament through a heated nozzle layer by layer until the object is complete.
In addition to plastic, other materials such as metal, ceramics, concrete, and even chocolate can be used in extrusion 3D printing.
Plastic extrusion 3D printing offers advantages such as speed, low cost, and versatility. It is accessible to both amateurs and professionals, making it a popular choice in various industries, including aerospace, automotive, and medicine.
