FDM vs FFF: Understanding 3D Printing Technologies

Fused Deposition Modeling (FDM) and Fused Filament Fabrication (FFF) are cornerstone technologies in additive manufacturing.

Both FDM & FFF create three-dimensional objects by extruding melted thermoplastic filament through a nozzle, building up layers to form the final product. The distinction between FDM and FFF lies not in the technology itself, but in their origins.

Stratasys developed and trademarked FDM in 1989 as their proprietary process. The RepRap project later coined FFF in 2005 as a generic term describing the same method, allowing its use by any manufacturer. FDM and FFF printers share common components: an extruder for heating and depositing filament, a build platform, motors for movement, and a filament feeding system.

The printing process for both technologies involves heating thermoplastic to its melting point, extruding it through a nozzle, and depositing material layer by layer based on a 3D model. As each layer cools, it bonds to the one below. Common materials include PLA, ABS, and PETG, along with specialty filaments. This approach to 3D printing is valued for its accessibility, cost-effectiveness, and ability to produce functional prototypes and parts across diverse industries. To maximize your success with FDM/FFF printing, it's essential to understand design best practices for this technology.

FDM meaning: Fused deposition modeling explained

Fused deposition modeling (FDM) is an additive manufacturing technique that builds three-dimensional objects by depositing melted thermoplastic in precise layers. Stratasys coined the term "FDM" when they developed and patented this method in 1989.

FDM technology centers on extruding heated material through a nozzle, constructing objects layer by layer, using thermoplastic filaments, and controlling the deposition process via computer. An FDM 3D printer typically consists of an extruder for heating and depositing filament, a build platform, motors for movement, and a filament feeding mechanism.

The printing process begins by heating thermoplastic filament to its melting point. The printer then extrudes this molten plastic through a nozzle, depositing it in layers according to the 3D model. Each layer cools and bonds to the previous one, gradually forming the complete object. FDM's strengths lie in its affordability, wide material compatibility, and ability to create functional prototypes and end-use parts. It finds applications in automotive, aerospace, and consumer goods industries.

While Stratasys trademarked "FDM," the same technology is known as Fused Filament Fabrication (FFF) when used by other manufacturers. In practice, these terms are often used interchangeably in the 3D printing field.

FFF acronym meaning: Fused filament fabrication defined

Fused filament fabrication (FFF ) is a 3D printing method that creates objects by depositing melted thermoplastic in precise layers.

The RepRap project introduced the term "FFF" in 2005 as a non-trademarked alternative to "Fused Deposition Modeling" (FDM).

Identically to FDM, FFF technology involves extruding melted thermoplastic through a heated nozzle, building objects layer by layer under computer control, using various thermoplastic materials as printing filament.

For those looking to explore FFF technology, desktop 3D printers like the Sketch Sprint or UltiMaker 3 offers an excellent entry point for both beginners and professionals.

Comparing FDM and FFF to other 3D printing technologies

FDM and FFF differ significantly from other additive manufacturing technologies like SLA (stereolithography) and SLS (selective laser sintering). Comparing FDM/FFF to SLA reveals differences in materials (thermoplastic filaments vs. liquid photopolymer resins), printing process (extrusion of melted plastic vs. curing resin with UV light), resolution (SLA typically achieves higher resolution and smoother surfaces), and applications (FDM/FFF suits functional prototypes, while SLA excels in detailed models and jewelry).

When comparing FDM/FFF to SLS, notable differences include materials (filaments vs. powdered materials, usually nylon), printing process (depositing material layer-by-layer vs. sintering powder with a laser), strength (SLS parts often exhibit greater strength and suitability for functional components), and complexity (SLS can produce more intricate geometries without support structures).

FDM/FFF technologies offer advantages such as lower entry costs for both printers and materials, a wider range of thermoplastic options, easier material changes and multi-material printing, and simpler post-processing. However, limitations include lower resolution and less smooth surface finish, visible layer lines, anisotropic strength (weaker in the Z-axis), and limited ability to produce complex internal structures.

When selecting between FDM/FFF and other technologies, consider factors like required resolution, material properties, cost, and intended application to determine the best fit for your specific needs. For those looking to explore the capabilities of FDM/FFF technology, UltiMaker offers a range of professional 3D printing solutions suitable for various applications and industries.