Industry-leading precision with best-in-class repeatability and layer adhesion. Manufacture using industrial-grade thermoplastics like ABS, ASA, PC, and ULTEM up to 36" × 24" × 36". Ideal for large-format prototypes, jigs, fixtures, and durable end-use components.
Industrial FDM systems deliver large-format capabilities with engineering-grade thermoplastics. From aerospace components to automotive tooling, FDM provides reliable, cost-effective manufacturing for demanding applications.
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.
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 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 × 609 × 914 mm.
Stable dimensional control suited for functional prototypes, jigs, and fixtures to ±0.25 mm or ±0.3%, whichever is greater.
Tuned for speed vs. finish; thicker layers for throughput, thinner for detail using 127 - 330 microns.
Forge Labs manufactures FDM parts using Fortus 900mc / 450mc.
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.
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
26 MPa
Flexural Modulus
1760 MPa
Temp Resistance
96 °C
Grade Selector
Compliance
UL 94 HB/RoHS Compliance/REACH Compliance
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
36 MPa
Flexural Modulus
2450 MPa
Temp Resistance
98 °C
Compliance
IEC 60093/ESD Association Standards/ANSI/ESD S20.20
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
No yield
Flexural Modulus
1760 MPa
Temp Resistance
103 °C
Grade Selector
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
30 MPa
Flexural Modulus
1800 MPa
Temp Resistance
138 °C
Applications
Automotive Dashboard Components/Aerospace Structural Components/Medical Device Housings/Manufacturing Tooling & Fixtures
High-Strength Composite Thermoplastic for Demanding Applications
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
41 MPa
Flexural Modulus
1900 MPa
Temp Resistance
110 °C
Grade Selector
Compliance
UL 94 V-0/RoHS Compliance/REACH Compliance
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
33 MPa
Flexural Modulus
2050 MPa
Temp Resistance
153 °C
Compliance
UL 94 V-0/14 CFR 25.853/AITM 2.0007B & 3.0005
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
41 MPa
Flexural Modulus
2230 MPa
Temp Resistance
216 °C
Compliance
UL 94 V-0/NSF 51 Food Contact/ISO 10993/USP Class VI
Applications
Composite Lay-up Tooling/Medical Instruments/Aerospace Components/Food Processing Equipment
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.
Visible Layer-by-Layer Texture
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
Chemically Smoothed Surface
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
Automotive-Grade Coating
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.
Tolerances
±0.25 mm or ±0.3%, whichever is greater
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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