Industrial FDM systems deliver large-format capabilities with engineering-grade thermoplastics including ABS, ASA, PC and ULTEM. Industry-leading precision, best-in-class repeatability and layer adhesion support demanding applications—from aerospace components and automotive tooling to jigs, fixtures and durable end-use parts. FDM provides reliable, cost-effective manufacturing for large-format prototypes and production components.
Advanced manufacturing capabilities enable complex geometries, functional prototypes, and end-use production parts that would be impossible or cost-prohibitive with traditional manufacturing methods. From functional prototypes to end-use production parts, this technology delivers exceptional performance across demanding industries.
Large Build Volume · Cost-Effective
Industrial Manufacturing
Trusted by manufacturers for large-scale production and industrial applications, FDM technology enables cost-effective manufacturing of oversized parts and complex assemblies. Engineering-grade thermoplastics like ULTEM, PEEK, and carbon fiber composites provide exceptional strength-to-weight ratios and chemical resistance. From aerospace ducting to automotive tooling, FDM offers unmatched scalability for both prototyping and end-use manufacturing with minimal material waste.
Manufacturing environments demand reliable, repeatable processes that FDM consistently delivers through heated chamber technology and precise material deposition. Large build volumes accommodate parts up to 900mm, while multi-axis capabilities enable complex overhangs and internal structures. The heated chamber ensures dimensional stability in engineering thermoplastics, critical for jigs, fixtures, and end-use components in demanding industrial applications.
Complex geometries: Intricate internal channels, overhangs, and assemblies impossible with traditional manufacturing.
Functional prototypes: Test mechanical properties and fit before investing in production tooling.
Custom tooling: Jigs, fixtures, and manufacturing aids tailored to specific production requirements.
End-use parts: Production components for aerospace, medical, automotive, and industrial applications.
Fused Deposition Modeling uses industrial Stratasys and Bambu Lab 3D printers with heated extruders and enclosed build chambers to melt and deposit thermoplastic filament layer by layer, creating strong, durable parts with excellent material properties. Controlled chamber heat minimizes warping on large parts and improves layer adhesion in engineering thermoplastics. Support material is removed after printing, leaving parts ready for post-processing.
Step 1 of 4
Industrial-grade thermoplastic filament is loaded into the heated extruder system. The enclosed build chamber is preheated to optimal temperature to prevent warping and ensure consistent layer adhesion.
Step 2 of 4
The heated extruder melts thermoplastic filament and deposits it according to the part geometry. Each layer bonds to the previous layer as it cools, building the part from bottom to top with precise temperature control.
Step 3 of 4
Soluble or breakaway support materials are deposited where needed for overhangs and complex geometries. Dual-extrusion systems enable different support materials for easy removal.
Step 4 of 4
Parts cool gradually in the controlled environment to prevent warping. Support materials are removed through chemical dissolution or manual breakaway, revealing the finished part ready for use or post-processing.
Large-format build envelopes allow oversized parts and fixtures to be produced in a single piece up to 914 x 609 x 914 mm.
Stable dimensional control suited for functional prototypes, jigs, and fixtures to ±0.3% (min ±0.25 mm).
Tuned for speed vs. finish; thicker layers for throughput, thinner for detail using 127 - 330 microns.
Forge Labs manufactures FDM parts using Stratasys Fortus 900, Stratasys Fortus 450, Stratasys Fortus 400, Bambu Lab H2S, Bambu Lab H2D, Stratasys Fortus 380, Markforged X7.
Professional-grade FDM thermoplastics engineered for strength, precision, and reliability. From standard engineering plastics to high-performance PEEK and carbon fiber composites, our material library covers applications from prototyping to end-use manufacturing.
ABS represents a proven choice for industrial FDM 3D printing, offering an excellent combination of mechanical strength, chemical resistance, and thermal stability.
This production-grade thermoplastic delivers consistent, reliable performance across automotive, aerospace, and manufacturing applications where durability and dimensional accuracy are paramount.
Industrial-Grade FDM Thermoplastic
Grade Selector
Compliance
UL 94 flammability
Applications
Marine antenna & sensor systems/Aerospace cabin retrofit tooling/Automation tooling & enclosures/Motorsport cooling & bracketry
ABS-ESD7 combines the proven mechanical properties and ease of processing of standard ABS with carbon additives that provide reliable electrostatic dissipative (ESD) properties.
With a surface resistance of 10⁷ Ω/sq, this material safely dissipates static charges within milliseconds, preventing damage to sensitive electronic components.
Electrostatic Dissipative Thermoplastic for Electronics
Compliance
ANSI/ESD S20.20, S11.11 and STM11.12
Applications
Electronic Jigs & Fixtures/Electronics Manufacturing/Semiconductor Handling/Automotive Electronics
ASA (Acrylonitrile Styrene Acrylate) is a high-performance thermoplastic designed for demanding outdoor applications.
It offers the mechanical strength of ABS with superior UV resistance, making it ideal for parts exposed to sunlight, weather, and environmental stress.
UV-Resistant Thermoplastic for Outdoor Applications
Grade Selector
Compliance
UL 94 flammability
Applications
Automotive Exteriors/Outdoor Equipment/Marine Applications/Architectural Elements
Stratasys FDM Polycarbonate represents the pinnacle of thermoplastic performance for additive manufacturing.
This advanced engineering material combines exceptional mechanical properties with superior thermal stability, making it the go-to choice for applications where standard thermoplastics fall short.
High-Performance Engineering Thermoplastic for Demanding Applications
Compliance
UL 94 flammability
Applications
Automotive Dashboard Components/Aerospace Structural Components/Medical Device Housings/Manufacturing Tooling & Fixtures
PC-ABS represents the perfect balance of strength, heat resistance, and processability for demanding FDM applications.
By combining polycarbonate's superior mechanical properties with ABS's excellent surface finish and moldability, this advanced thermoplastic blend delivers exceptional impact resistance (241 J/m notched Izod), high heat deflection temperature (up to 126°C), and outstanding dimensional stability.
Tough, Heat-Resistant PC/ABS Blend
Grade Selector
Compliance
UL 94 flammability
Applications
Automotive Interior Components/Electronics Housings/Consumer Product Prototypes/Manufacturing Tooling
ULTEM 9085 is considered an engineering grade Fused Deposition Modeling (FDM) thermoplastic renowned for its exceptional strength-to-weight ratio and flame-retardant properties.
This polyetherimide (PEI) blend offers superior mechanical performance and ease of printing, making it ideal for demanding engineering applications.
High-Performance Thermoplastic for Mission-Critical Applications
Compliance
UL 94 flammability/14 CFR 25.853 (FAR 25.853)/BSS 7238 & BSS 7239
Applications
Aerospace Interior Components/Automotive Under-Hood Components/Manufacturing Tooling/Electrical & Electronics
ULTEM 1010 is a high-performance polyetherimide (PEI) resin that represents the pinnacle of FDM thermoplastic performance.
With the highest heat resistance, chemical resistance, and tensile strength of any FDM material, ULTEM 1010 excels in the most demanding applications.
Highest Heat Resistance, Chemical Resistance & Tensile Strength of Any FDM Material
Compliance
UL 94 flammability/ASTM E595 (Outgassing)/NSF 51 (Food equipment materials)
Applications
Composite Lay-up Tooling/Medical Instruments/Aerospace Components/Food Processing Equipment
Antero 800NA is a groundbreaking PEKK-based (polyetherketoneketone) FDM thermoplastic that sets new standards for high-performance additive manufacturing.
Combining excellent mechanical properties including high strength, heat resistance, and toughness with superior chemical resistance and ultra-low outgassing characteristics, it excels in the most demanding aerospace, space, and industrial applications.
Aerospace-Grade Thermoplastic with Exceptional Chemical Resistance & Low Outgassing
Compliance
14 CFR 25.853 (FAR 25.853)/BSS 7238 & 7239/AITM 2.0007B & 3.0005
Applications
Aerospace Components/Spacecraft Parts/Chemical Processing Equipment/High-Temperature Tooling
PAHT-CF Carbon Fiber Nylon is a composite material that combines a nylon 12-based polymer with chopped carbon fiber at 12–20% by weight.
It is stiff, light and heat resistant, with a heat deflection temperature of 170 °C at 1.
Carbon Fiber Reinforced Thermoplastic for High-Performance Applications
Compliance
RoHS Directive 2011/65/EU (amended by EU 2015/863)
Applications
Aerospace Structural Components/Automotive Performance Parts/Manufacturing Jigs & Fixtures/End-of-Arm Tooling
Stratasys TPU 92A brings elastomeric performance to FDM, with properties documented by build axis on the Stratasys F123 and F123CR platforms.
The material combines Shore A 92 hardness with high elongation at break (552% XY / 482% XZ), making it practical for compliant parts that repeatedly flex.
Stratasys FDM TPU Elastomer (Shore 92A)
Applications
Flexible Hoses & Tubes/Seals & Gaskets/Vibration Dampeners/Protective Covers
Industrial-Grade FDM Thermoplastic
ABS represents a proven choice for industrial FDM 3D printing, offering an excellent combination of mechanical strength, chemical resistance, and thermal stability. This production-grade thermoplastic delivers consistent, reliable performance across automotive, aerospace, and manufacturing applications where durability and dimensional accuracy are paramount.
Tensile Strength
30.8 MPa
Flexural Modulus
2220 MPa
Temp Resistance
104.4 / 103.2 °C
Grade Selector
Compliance
UL 94 flammability
Applications
Marine antenna & sensor systems/Aerospace cabin retrofit tooling/Automation tooling & enclosures/Motorsport cooling & bracketry
Electrostatic Dissipative Thermoplastic for Electronics
ABS-ESD7 combines the proven mechanical properties and ease of processing of standard ABS with carbon additives that provide reliable electrostatic dissipative (ESD) properties. With a surface resistance of 10⁷ Ω/sq, this material safely dissipates static charges within milliseconds, preventing damage to sensitive electronic components.
Tensile Strength
35.4 MPa
Flexural Modulus
2410 MPa
Temp Resistance
104.6 °C
Compliance
ANSI/ESD S20.20, S11.11 and STM11.12
Applications
Electronic Jigs & Fixtures/Electronics Manufacturing/Semiconductor Handling/Automotive Electronics
UV-Resistant Thermoplastic for Outdoor Applications
ASA (Acrylonitrile Styrene Acrylate) is a high-performance thermoplastic designed for demanding outdoor applications. It offers the mechanical strength of ABS with superior UV resistance, making it ideal for parts exposed to sunlight, weather, and environmental stress.
Tensile Strength
32.8 / No yield MPa
Flexural Modulus
1980 / 1760 MPa
Temp Resistance
103 / 102 °C
Grade Selector
Compliance
UL 94 flammability
Applications
Automotive Exteriors/Outdoor Equipment/Marine Applications/Architectural Elements
High-Performance Engineering Thermoplastic for Demanding Applications
Stratasys FDM Polycarbonate represents the pinnacle of thermoplastic performance for additive manufacturing. This advanced engineering material combines exceptional mechanical properties with superior thermal stability, making it the go-to choice for applications where standard thermoplastics fall short.
Tensile Strength
93.9 MPa
Flexural Modulus
3430 MPa
Temp Resistance
144.0 / 144.3 °C
Compliance
UL 94 flammability
Applications
Automotive Dashboard Components/Aerospace Structural Components/Medical Device Housings/Manufacturing Tooling & Fixtures
Tough, Heat-Resistant PC/ABS Blend
PC-ABS represents the perfect balance of strength, heat resistance, and processability for demanding FDM applications. By combining polycarbonate's superior mechanical properties with ABS's excellent surface finish and moldability, this advanced thermoplastic blend delivers exceptional impact resistance (241 J/m notched Izod), high heat deflection temperature (up to 126°C), and outstanding dimensional stability.
Tensile Strength
36.5 MPa
Flexural Modulus
1.86 GPa
Temp Resistance
117.9 °C
Grade Selector
Compliance
UL 94 flammability
Applications
Automotive Interior Components/Electronics Housings/Consumer Product Prototypes/Manufacturing Tooling
High-Performance Thermoplastic for Mission-Critical Applications
ULTEM 9085 is considered an engineering grade Fused Deposition Modeling (FDM) thermoplastic renowned for its exceptional strength-to-weight ratio and flame-retardant properties. This polyetherimide (PEI) blend offers superior mechanical performance and ease of printing, making it ideal for demanding engineering applications.
Tensile Strength
69.2 MPa
Flexural Modulus
2400 MPa
Temp Resistance
178.2 / 178.4 °C
Compliance
UL 94 flammability/14 CFR 25.853 (FAR 25.853)/BSS 7238 & BSS 7239
Applications
Aerospace Interior Components/Automotive Under-Hood Components/Manufacturing Tooling/Electrical & Electronics
Highest Heat Resistance, Chemical Resistance & Tensile Strength of Any FDM Material
ULTEM 1010 is a high-performance polyetherimide (PEI) resin that represents the pinnacle of FDM thermoplastic performance. With the highest heat resistance, chemical resistance, and tensile strength of any FDM material, ULTEM 1010 excels in the most demanding applications.
Tensile Strength
79.2 MPa
Flexural Modulus
2910 MPa
Temp Resistance
216.9 / 217.1 °C
Compliance
UL 94 flammability/ASTM E595 (Outgassing)/NSF 51 (Food equipment materials)
Applications
Composite Lay-up Tooling/Medical Instruments/Aerospace Components/Food Processing Equipment
Aerospace-Grade Thermoplastic with Exceptional Chemical Resistance & Low Outgassing
Antero 800NA is a groundbreaking PEKK-based (polyetherketoneketone) FDM thermoplastic that sets new standards for high-performance additive manufacturing. Combining excellent mechanical properties including high strength, heat resistance, and toughness with superior chemical resistance and ultra-low outgassing characteristics, it excels in the most demanding aerospace, space, and industrial applications.
Tensile Strength
86.7 MPa
Flexural Modulus
3,200 MPa
Temp Resistance
158 / 158 °C
Compliance
14 CFR 25.853 (FAR 25.853)/BSS 7238 & 7239/AITM 2.0007B & 3.0005
Applications
Aerospace Components/Spacecraft Parts/Chemical Processing Equipment/High-Temperature Tooling
Carbon Fiber Reinforced Thermoplastic for High-Performance Applications
PAHT-CF Carbon Fiber Nylon is a composite material that combines a nylon 12-based polymer with chopped carbon fiber at 12–20% by weight. It is stiff, light and heat resistant, with a heat deflection temperature of 170 °C at 1.
Tensile Strength
92 / 47 MPa
Flexural Modulus
4230 / 1820 MPa
Temp Resistance
194 °C
Compliance
RoHS Directive 2011/65/EU (amended by EU 2015/863)
Applications
Aerospace Structural Components/Automotive Performance Parts/Manufacturing Jigs & Fixtures/End-of-Arm Tooling
Stratasys FDM TPU Elastomer (Shore 92A)
Stratasys TPU 92A brings elastomeric performance to FDM, with properties documented by build axis on the Stratasys F123 and F123CR platforms. The material combines Shore A 92 hardness with high elongation at break (552% XY / 482% XZ), making it practical for compliant parts that repeatedly flex.
Tensile Strength
15.6 MPa
Flexural Modulus
25.6 / 36.9 MPa
Temp Resistance
38 °C
Applications
Flexible Hoses & Tubes/Seals & Gaskets/Vibration Dampeners/Protective Covers
FDM parts have a distinct layer-by-layer texture with visible striations, resulting in a slightly rough, ribbed surface finish. While the natural finish is durable and functional for most applications, post-processing techniques can significantly enhance appearance and performance. Vapor smoothing chemically melts the outer surface, creating a glossy, sealed finish with improved strength. Performance painting provides a professional, polished look with custom color matching capabilities.
FDM 3D printed parts have a visible layer-by-layer texture with slight ridges and striations, resulting in a rougher surface finish compared to other 3D printing technologies like SLS or SLA. Soluble supports are dissolved in an ultrasonic cleaning tank, while physical supports on high-temperature materials are removed by hand if required.
Finish attributes
Vapor smoothing dissolves the outer layer, causing it to smooth out and blend, reducing layer lines and enhancing the part's appearance. This process creates a glossy, sealed surface with improved strength, reduced porosity, and increased chemical resistance, making it ideal for functional and aesthetic applications.
Finish attributes
Painting offers a highly durable, automotive-grade coating that enhances the aesthetics and durability of 3D-printed parts. Each part is hand-finished to ensure smooth surfaces and a premium quality appearance. Using professional-grade coating equipment, this process allows for precise application and exceptional adhesion. Custom color matching is available, making it ideal for applications that require specific branding or visual impact.
Finish attributes
Large-format thermoplastics benefit from secondary operations that improve assembly accuracy and in-field durability.
Threading and tapping
Production-safe threaded features for repeated install/remove cycles.
Heat-set insert programs
Higher pull-out strength for enclosures, brackets, and service panels.
Bonding and sub-assembly
Joinery workflows for oversized geometry split across multiple builds.
Our design guidelines for Fused Deposition Modeling (FDM) include important information to improve part quality, minimize costs, and reduce overall manufacturing time. This section is a quick primer before full DFM review.
Maximum Build Volume
914mm x 609mm x 914mm (36" x 24" x 36")
FDM produces parts up to 36 inches in a single build.
General Tolerances
±0.3% (min ±0.25 mm)
Industrial FDM achieves tolerances of ±0.
Minimum Wall Thickness
1.0mm (0.039")
Supported walls are connected to two or more sides and are thick enough to support the model.
Layer Height
127 - 330 microns
Standard layer height is 254 microns (0.
Fused Deposition Modeling offers unique advantages for modern manufacturing applications, delivering exceptional performance and versatility for both prototyping and production requirements. Key benefits include cost-effective manufacturing, superior material properties, and the ability to produce complex geometries that would be impossible or expensive with traditional manufacturing methods.
Upload files, configure manufacturing specs, and track production in one workflow built for engineering teams.
75% complete
Step 01
Automated file checks before production
Drop your CAD files and receive immediate manufacturability feedback. Critical geometry and wall checks run as soon as files are uploaded.
Industrial FDM is used when programs need large-format capability, rugged thermoplastics, and cost-effective iteration. Teams rely on FDM for tooling, fixtures, enclosures, ducting, and oversized prototypes that must hold up in real environments.
FDM is typically chosen for big parts, high-temperature polymers, and shop-floor tooling where strength and size matter more than fine surface finish. It supports rapid iteration and practical production aids that shorten setup time in manufacturing.
Full-scale tooling, fixtures, and functional prototypes.
Example parts
Layup tools, interior panels, test fixtures, and qualification prototypes.
Why it fits: FDM offers the largest build volumes with aerospace-certified thermoplastics like ULTEM, enabling full-scale tooling and functional prototypes for qualification testing.
Structural base elements and large-scale terrain forms.
Example parts
Structural base models, terrain forms, and large-volume massing elements.
Why it fits: FDM's large build volume handles structural base elements and terrain forms cost-effectively, providing robust foundations for detailed model assemblies.
Full-scale interior and under-hood prototyping.
Example parts
Dashboard prototypes, interior trim panels, and large under-hood components.
Why it fits: FDM's large build volume and engineering-grade materials enable full-scale prototyping of dashboards, panels, and under-hood components for assembly validation.
Highlighted Case Study
Marine manufacturing
ISE transitioned AUV components from machining to additive production, reducing cost and lead time while preserving the mechanical reliability needed for subsea deployment.
• Up to 73% cost reduction
• Lead time compressed to days
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STEP, STL, OBJ, 3MF and IGES supported
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