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Fused Deposition Modeling (FDM)

Production Grade Thermoplastics

Forge Labs offers a wide range of advanced thermoplastics identical to those used in traditional manufacturing processes, making it ideal for end-use parts, testing real-world material properties, or creating durable jigs, fixtures, and templates for production.

Choose FDM when you need strong, functional parts that are dimensionally stable. Parts produced on Stratasys Fortus machines offer the industry's best repeatability of any 3D printing technology and are ideal for manufacturing complex designs in a wide range of thermoplastics.

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100k+ 

Parts 3D Printed

± 0.15

MM Part Tolerances

14

Materials

2-5 Day

Average Lead Time

Thermoplastics| Fused Deposition Modeling

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ABS

https://forgelabs.com/fused-deposition-modeling-fdm/#ASA

UV Resistant 

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Flexible

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Strong

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Performance

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ABS-M30

Strongest Additive ABS Thermoplastic 

ABS-M30™ by Stratasys is up to 70 percent stronger than standard ABS, providing significantly better layer bonding, impact resistance and flextural strength than standard level consumer grade ABS. ABS-M30 highly cost effective solution, ideal material for numerous applications including conceptual modeling, functional prototyping, manufacturing tools such as jigs and fixtures as well as end-use production parts.

MEASUREMENT

VALUE

STANDARD

Tensile Strength, Yield

32 MPa

ASTM D638

Tensile Modulus

2,230 MPa

ASTM D638

Elongation at Break

4%

ASTM D648

Unnotched Izod Impact

283 J/m

ASTM D256

Heat Deflection Temperature

86°C @ 0.45 MPa

ASTM D648

All Details
Material Data Sheet
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PC-ABS

Strength, Heat Resistance & Flexibility 

Polycarbonate-ABS (PC-ABS) combines the desirable strength and heat resistant properties of PC with the flexibility & cost advantages of ABS. PC-ABS is one of the most widely used thermoplastics used in automotive, electronics and variety of other industrial manufacturing applications.

MEASUREMENT

VALUE

STANDARD

Tensile Strength, Yield

41 MPa

ASTM D638

Tensile Modulus

1,900 MPa

ASTM D638

Elongation at Break

6%

ASTM D648

Unnotched Izod Impact

481 J/m

ASTM D256

Heat Deflection Temperature

110°C @ 0.45 MPa

ASTM D648

All Details
Material Data Sheet
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ABS - ESD7

Static Dissipative 

ABS thermoplastic with static dissipative properties (ABS-ESD7) is ideal for applications where a static charge can damage products, impair their performance or cause an explosion. ABS-ESD7 prevents static electricity build up so that it will not produce static shock while also preventing fine powders & dust from sticking. ABS-ESD7 is widely used in electronic manufacturing industries for creating jigs and fixtures, enclosures and packaging.

MEASUREMENT

VALUE

STANDARD

Tensile Strength

35 MPa

ASTM D638

Tensile Modulus

2,400 MPa

ASTM D638

Elongation at Break

3.4%

ASTM D638

Unnotched Izod Impact

55 J/m

ASTM D256

Heat Deflection Temperature

96°C @ 0.45 MPa

ASTM D648

All Details
Material Data Sheet
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ASA

UV Stable ABS Thermoplastic 

ASA provides the same mechanical properties as ABS-M30 along with enhanced UV stability, making it ideal for outdoor applications. Combined with good impact resistance, toughness and aesthetics, ASA is one of the most broadly used thermoplastics, ideal for concept models, functional production parts such as jigs, fixtures, working prototypes and manufacturing tools.

MEASUREMENT

VALUE

STANDARD

Tensile Strength

33 MPa

ASTM D638

Tensile Modulus

2,010 MPa

ASTM D638

Elongation at Break

5.9%

ASTM D638

Unnotched Izod Impact

285 J/m

ASTM D256

Heat Deflection Temperature

102°C @ 0.45 MPa

ASTM D648

All Details
Material Data Sheet
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Nylon 12

Tough Parts With Superior Elongation 

Ideal for creating durable end-use parts with high fatigue and chemical resistance. FDM Nylon 12 exhibits up to 300% better elongation and fatigue resistance than other FDM materials along with superior chemical compatibility for the most demanding applications such as repetitive enclosures, snap fits and vibration-resistant parts.

MEASUREMENT

VALUE

STANDARD

Tensile Strength, Yield

46 MPa

ASTM D638

Tensile Modulus

1,282 MPa

ASTM D638

Elongation at Break

30%

ASTM D648

Unnotched Izod Impact

200 J/m

ASTM D256

Heat Deflection Temperature

97 °C @ 0.45 MPa

ASTM D648

All Details
Material Data Sheet
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Polycarbonate

High Tensile Strength For Demanding Prototyping

Polycarbonate provides exceptionally high tensile and flexural strength, making it ideal for manufacturing strong parts, tooling and fixtures. FDM Polycarbonate is a widely used thermoplastic in automotive, aerospace, medical and a variety of other applications for applications where accuracy, durability and stability are critical.

MEASUREMENT

VALUE

STANDARD

Tensile Strength

57 MPa

ASTM D638

Tensile Modulus

1,944 MPa

ASTM D638

Elongation at Break

4.8%

ASTM D638

Unnotched Izod Impact

877 J/m

ASTM D256

Heat Deflection Temperature

138°C @ 0.45 MPa

ASTM D648

All Details
Material Data Sheet
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ULTEM  9085

Highest Strength-to-Weight Ratio 

ULTEM 9085 by Sabic is a high performance polyetherimide thermoplastic offering excellent strength- to weight ratio and FST (flame, smoke, toxicity) ratings. Ideal for demanding applications, these properties make ULTEM 9085 a great choice for direct manufacturing of fully functional parts, prototypes and tooling with ultra fast lead times.

MEASUREMENT

VALUE

STANDARD

Tensile Strength

70 MPa

ASTM D638

Tensile Modulus

2,510 MPa

ASTM D638

Elongation at Break

5.3%

ASTM D638

Unnotched Izod Impact

781 J/m

ASTM D256

Heat Deflection Temperature

153°C @ 0.45 MPa

ASTM D648

All Details
Material Data Sheet
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ULTEM  1010

Highest Tensile Strength, Heat & Chemical Resistance 

ULTEM 1010 is a high performance thermoplastic resin used to create fully functional parts ideal for aerospace & automotive manufacturing industries. ULTEM 1010 offers the highest heat resistance, chemical resistance and tensile strength of any additive thermoplastic.

MEASUREMENT

VALUE

STANDARD

Tensile Strength

81 MPa

ASTM D638

Tensile Modulus

2,770 MPa

ASTM D638

Elongation at Break

3.3%

ASTM D638

Unnotched Izod Impact

326 J/m

ASTM D256

Heat Deflection Temperature

216 °C @ 0.45 MPa

ASTM D648

All Details
Material Data Sheet
 

Design Guidelines | Fused Deposition Modeling

  • Minimum Wall Thickness:

1 mm

  • Engraved Details

Thickness of 1 mm & depth of 0.3 mm

  • Embossed Details

Thickness of 1 mm & depth of 0.5 mm

  • Unsupported Wall Size

3 mm

  • Minimum Hole Size

0.5 mm

  • Layer Height

125 μm- 330 μm

  • Maximum Build Size

914 x 610 x 914 mm (36 x 24 x 36 in.)

  • Tolerances

± .127 mm (± .005 in.) or ± .0015 mm/mm

  • Anisotropy

Decreased material properties perpendicular to layer lines.

  • Support

Support is soluble for most FDM plastics & does not leave defects.

Advantages of Fused Deposition Modeling

  • Rapid Turnaround

    The spacious build tray allows for orders to be shipped within 2-4 business days

  • Flexible

    Specialized materials suitable for high fatigue applications, such as snap fits and friction fit inserts.

  • Durable

    Durable prototypes built in the same production grade thermoplastics used in injection molding and CNC machining

  • Large Builds

    Produce parts with build volumes up to 36″ x 24″ x 36″, to produce large, complex parts in a single build.

  • Low Cost Per Part

    FDM is one of the most economical 3D Printing technologies, making it ideal for tight budgets

  • Versatile Materials

    Specialized materials for electrostatic dissipation, translucence, biocompatibility, UV Resistance, VO flammability, and FST ratings.

Case Studies | Fused Deposition Modeling

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Replacing Traditionally Machined Parts with FDM

Published 25/08/2018

International Submarine Engineering has been able to replace traditionally machined parts on their newest Explorer class AUVs with 3D printed parts.

Read Case Study
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3D Printing Architecture

Published 06/03/2020

Together with the rapid print speed and the affordability of FDM - makes it possible for us to provide massing models faster and more affordably than via traditional manufacturing methods.

Read Case Study
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FFF vs FDM 3D Printing: Explained

Published 21/04/2019

This article explores the differences between fused filament fabrication (FFF) and Fused Deposition Manufacturing (FDM).

Read Case Study