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Fused deposition modeling (FDM) was developed with a grant from NASA by Advanced Ceramics Research (ACR) in Tucson, AZ. The patent on the process is held by Stratasys Inc.

A geometric model is designed on a CAD software. After a .STL file is created, it is imported into a specialized software, QuickSlice, that mathematically slices the conceptual three-dimensional CAD model into very thin layers or cross-sections. This program incorporates the SupportWorks program that designs the necessary supports needed for building the part. These programs process the design on a workstation and also serve as the interface with the actual machine. The information is then sent to the machine for production.

Upon activation, the machine calibrates itself automatically. Once the design has been transferred, the thermoplastic modeling material is heated to one degree Fahrenheit above the materials melting point and sent through a pressurized channel to a pump. The extrusion head deposits the material in ultra-thin layers which is held in vacuum in order to reduce movement. It solidifies within 0.1 seconds after leaving the extrusion head. As each layer is extruded, it bonds to the previous layer and solidifies.

The head directs the material into place with precision. The devices are electro-magnetically driven to reduce friction and shaking due to outside movement.

 

Material Deposition in FD Process