Fused

Deposition

Modeling (FDM)

One of the key advantages of FDM is its cost efficiency. Compared to other additive manufacturing technologies, both the initial investment in printers and material costs are relatively low. This makes FDM particularly attractive for companies that require rapid and economical prototyping, as well as for small-series production where injection molding would be uneconomical.

Another strong point is its ease of use. Modern FDM printers feature automated calibration systems and intuitive user interfaces, making it relatively simple to adopt the technology. Additionally, many systems support open material platforms, allowing the use of a wide variety of filaments—from standard plastics like PLA and ABS to specialized materials with enhanced mechanical or thermal properties.

FDM-produced components can also be mechanically durable and robust. Especially in thick-walled or solid structures, materials such as ABS, PETG, or Nylon offer high stability. In industrial applications, high-performance polymers like PEEK or ULTEM are increasingly used, as they withstand high temperatures, chemical exposure, and mechanical wear.

Another advantage is the scalability of the technology. FDM printers come in various sizes—from small desktop devices for prototyping to large-format machines capable of printing functional parts. Printing parameters can be individually adjusted to meet specific requirements for dimensional accuracy, strength, and surface quality.

Despite its many advantages, the FDM process has some technical limitations that must be considered depending on the application.

One of the biggest challenges is its limited detail resolution. Compared to technologies such as SLA (Stereolithography) or SLS (Selective Laser Sintering), FDM offers lower precision because parts are constructed layer by layer from molten material. This results in visible layer lines on the surface, often requiring post-processing to achieve a smoother finish or higher dimensional accuracy.

Another disadvantage is the anisotropic material properties of FDM parts. Since printing occurs in layers, the bond between these layers is weaker than within a single layer. The mechanical strength of an FDM component is therefore highly dependent on its print orientation. Generally, partsexhibit greater strength along the print plane than perpendicular to it, which must be considered in high-load applications.

Additionally, FDM often requires support structures when printing overhangs or complex geometries. These support materials must be removed after printing, increasing post-processing effort and material costs. This can be particularly challenging for delicate parts, as removing supports can impact dimensional accuracy and surface quality.

A further limiting factor is the material selection for high-performance applications. While standard filaments like PLA and ABS are widely available, technical high-performance plastics such as PEEK or ULTEM require specialized printers with higher processing temperatures and optimized process control.

FDM enables the rapid and economical production of functional prototypes. In product development, components can be manufactured, tested, and iterated within hours—without the need for expensive tooling.

FDM is also ideal for small-series production, particularly for custom enclosures, spare parts, or specialized components. Companies can respond flexibly to customer requirements without investing in costly manufacturing tools.

Beyond end-use products, FDM is also used to produce tools, clamping fixtures, and inspection gauges. Particularly for single-piece or low-volume production, the process offers a cost-effective and fast alternative to traditional CNC machining.

The use of high-performance polymers such as PEEK or ULTEM allows for the production of lightweight, durable components that withstand high temperatures and mechanical stresses.

FDM also enables on-demand manufacturing of replacement parts, reducing inventory costs.

FDM is used to manufacture patient-specific prosthetics, orthotics, and anatomical models.

These enhance individualized treatment and improve surgical planning.