FDM 3D Printing

TEAM Lab Hardware

Bambu Lab X1C

 

Build Volume: 256 x 256 x 256 mm

Max Extruder Temperature: 300°C

Materials: PLA, ABS, PETG, TPU, PA (Nylon), PC, ASA, PET, Fiber-Infused polymers (Nylon, ABS, PLA, PETG), PVA (Water-soluble), HIPS, and more

Unique Properties:

• Multi-material capabilities provided by "Automatic Material Switcher"
• Fastest FDM printing option offered by team (same day or next day turnaround in most instances)

Link to manufacturer's website

Prusa XL

Build Volume: 360x360x360 mm

Max Extruder Temperature: 290°C

Materials: PLA, ABS, PETG, TPU, PA (Nylon), PC, ASA, PET, PVA (Water-soluble), HIPS, and more

Unique Properties:

• Multi-material capabilities provided by 5 discrete tool-heads
• Our largest available FDM XY build volume 

Link to manufacturer's website

Vision Miner 22 IDEX v2

Build Volume: 350x 350x 450mm

Max Extruder Temperature: 500°C

Materials: All basic filaments plus: PEEK, PEI (Ultem), PC, etc. See manufacturer's site for full chart.

Unique Properties

• Compatibility with high-performance polymers (Amorphous and semi-crystalline) that require extremely high extrusion temperatures, and a heated build envelope.  
• Dual extrusion heads for dedicated support materials.

Link to manufacturer's website

Voron 2.4

Build Volume: 350x 350x 350mm

Max Extruder Temperature: 350°C

Materials: PLA, ABS, PETG, TPU, PA (Nylon), PC, ASA, PET, PVA (Water-soluble), HIPS, and more

Unique Properties

• Open-source platform allows us to retrofit this machine for alternative applications including but not limited to paste extrusion printing.

Link to Voron project website

Stratasys F-120

Build Volume: 254x254x254mm

Max Extruder Temperature: 300°C

Materials: White ASA, H2O soluble supports (SR-30 Support)

Unique Properties

• Dedicated secondary nozzle for water-soluble supports

Link to manufacturer's website

Filabot EX2

 

• This is not a 3D printer, but rather a filament extruder.  With this machine, we have the ability to design custom thermoplastic filaments for use in our above printers.

Compatible Materials: PLA, ABS, PETG, TPU, PA (Nylon), PC, ASA, PET, Fiber-Infused polymers (Nylon, ABS, PLA, PETG), PVA (Water-soluble), PEEK, more.

Maximum Drive Force: 85in lbs (9.6Nm)

Output Filament Diameter: 1.75mm, 2.85mm, Custom (up to 4mm)

Unique Properties:

• Compound your own custom thermoplastic filaments for use in our 3D printers (or yours)
• Wide range of input materials

Link to manufacturer's website

Materials

Comparison to other printing technologies

Examples:

FDM Printing Gallery

Click here to view more example FDM prints.

Rates

• Note: We strongly recommend submitting a service request to obtain an accurate project cost estimate. Self-quoting can often lead to miscalculations
• Already have a quote from another vendor?  Share it with us and we'll match or beat it. 

We bill for time and materials while using our FDM printers. For time, we assess 0.5 hours of assisted time per-print tray plus an hourly rate for machine use. Maximizing tray capacity with your parts—whether identical or varied—significantly reduces per-unit part cost.

Estimating project cost should be left to TEAM, but here are some general project estimates that can guide in self-estimating:

*All declared values at internal rates, NUD = university required "Non-University Differential" added for external.

Optional Post Processing Services

Epoxy Coating

If your FDM print necessitates a smooth surface finish, we can clad your prints in an epoxy coating to fill in surface defects.  We stock, and use Smooth-On XTC-3D:

Supports removal

Generally, we will do our best to remove supports as part of our basic service.  However, if printing a very complicated part (with difficult to access supports, or a large volume of supports), we may assess additional time to cover the cost of support removal OR provide the part with supports for you, the client, to remove.

Threaded holes

Threads are generally not directly printed onto parts, but are instead added as a secondary process by way of tapping. Exceptions may occur where two bodies are designed to couple/decouple by way of coarse threads. Other (superior) techniques for adding threads involve using threaded inserts (usually brass), or capturing a nut; Both of these techniques result in much more durable threads than a printed part alone.

Custom Material Manufacturing

We have the hardware necessary to manufacture our own custom blends of thermoplastic compatible with FDM printing.  Further, our Voron 2.4 is an open-source design which allows us to consider other deposition processes (including but not limited to paste extrusion).

Preparing Files for Printing:

The team lab suggests two sets of files for each 3D printed part (where possible) – the original parametric model file (Solidworks/Inventor/Fusion360/etc), and a millimeter scale STL file (point-mesh file).  Please include these files on your project request if possible. 

For multi-material prints, we require one STL file for each material in a shared coordinate system. Please work with TEAM lab staff to ensure this constraint is satisfied.

Technical Details

Surface Finish

FDM prints will generally present to an informed individual as being printed; layer lines will be visible, and traces will be apparent along upward or downward facing faces.  Our more advanced printing technologies (Resin Printing) will present with a much more consistent outward surface finish. 

Support Material and Consequential Defects

Overhanging features often necessitate the existence support structure (often made of the build material) which must be mechanically removed.

As FDM printing relies on adhesion to the build platform, or a previous layer below for the extruded filament to stick, some prints may require support structures where overhangs become too severe. Else, drooping, or failed printing may occur.  These features are removed upon completion of the print, as a post-processing routine.   In the instance that supports are needed, expect subtle print defects at locations where supports are used (rougher finish, mild drooping, etc). Through careful and intentional design, often times support structure can be avoided.  Please see the figures below for an example of this property:

Layer thickness

We generally print our FDM parts at a layer thickness of 0.2mm unless otherwise asked.

Default infill and Shell Count

We generally print our FDM prints with a default shell count of 5 (to accommodate tapping operations) and 20% infill.  If you need alternative settings, please define those upon project submission. 

While thick walls result in stronger parts, too many “shells” can result in print defects that lead to poor surface finish, or warping.  

• Actual wall thickness (dimension) is a multiple of the Nozzle diameter (typically 0.4mm), aka 1 “shell” thickness.

• Above Figure: Different Shell-Counts (via prusaprinters.org)

Minium Feature Size

Generally speaking, we advise a minimum feature size in excess of 1mm.  This is not a hard-and-fast value; there are many variables that dictate if a feature can or cannot be realized via this technology.  

• Note that we assess all prints for viability prior to starting as part of our general service to you; if we see a feature that is concerning, we will make direct and immediate contact to convey our concerns and help brainstorm a solution.  

Thermoplastics

FDM printing is physically limited to thermoplastics; specifically, polymers that can be found on or made into a filament. 

• The TEAM lab does offer custom filament extrusion as a service - inquire for more details

Hollow Prints

Parts derived from this technology are rarely solid; instead, they are generally created in a series of “shells” extending from the outside surface inward, coupled with an “infill” to provide bulk-support. 

• This process is achieved within the printing/slicing software, not within CAD.

• Above Figure: Zoomed Depiction of 3D Print Cross-Section

Infill – This parameter adjusts how solid the interior of a part is. Low values (10-15%) reduce print time, and decrease weight with minimal impact on strength. High Values (15-25%) increase strength, but increase print time and can cause distortion. Very-High Values (25%+) can cause severe warping.

• Above Figure: Infill Percentages (via zx3d.com.au)

• Above Figure: Different Infill Patterns, all 30% fill (via Makerbot)

Distortion:

Due to thermal contraction, all FDM prints can be prone to distortion from their intended geometry. The following parameters are major factors in this process:

Aspect ratio 

As a part becomes long, relative to its width, thermal distortion is more likely (bowing). Occasionally, this distortion can become so bad that prints fail due to the nozzle knocking against the print, causing it to detach from the built platform. It’s generally recommended to limit prints to a 5:1 length to width ratio (or smaller).

• Above Figure: Intended Part with Large Aspect Ratio (via Markforged)

• Above Figure: Resultant Part is Warped (via Markforged)

Physical Size

Large prints are generally more likely to experience thermal distortion.  

Sharp Corners

Sharp corners (~90 degrees) engaged with the print-surface can (in some cases) cause peeling/warping away from the build platform, where parts have a large footprint. To counteract this, we often recommend adding “Lilly pads” AKA “dog-ears” to the base of prints to encourage good adhesion. These features are then clipped off afterwards with little effect on the finished print. TEAM lab Tools and Techniques – FDM 3D Printing TEAM@UCD BME, Revised JUNE2018

• Above Figure: Warped Corner, no Lilly pad/Dog-ear (via Ultimaker) 

• Above Figure: Sacrificial Anti-Warp Features Added to a 3D Print underside (via Thingiverse)

Safety

All materials must meet approval by the TEAM lab prior to printing for the protection of our staff and hardware.  If you wish to use something other than our standard offerings, we are open to the concept but please inquire for specifics!