Fused Deposition Modeling: How it works.

FDM builds three-dimensional parts by melting and advancing a fine ribbon of plastic through a computer-controlled extrusion head, producing parts that are ready to use. The automated three-step process is quick and simple:
 

1. PRE-PROCESSING (“slicing” or sectioning CAD design into layers)

The FDM process begins in one of two build-preparation programs, Catalyst EX or Insight.

 

In operation, your first step is to import a design file, pick options, and create slices (layers). The preprocessing software calculates sections and “slices” the part design into many layers, ranging from 0.005 inches (0.127 mm) to 0.013 inches (0.3302 mm) in height. Using the sectioning data, the software then generates “tool paths” or building instructions which will drive the extrusion head. This step is automatic when using Catalyst EX. Next send the job to the 3D printer.
 

2. PRODUCTION (the layering process) Press “print” to start the building process.

Two materials, one to make the part, and one to support it, enter the extrusion head. Heat is applied to soften the plastics, which are extruded in a ribbon, roughly the size of a human hair. Alternating between part material and support material, the system deposits layers as thin as 0.005 inch (0.13 mm).
 

3. POST-PROCESSING (removing disposable support material)

When the part is complete, open the chamber and remove it. Finish up by either washing or stripping away the support material that held the part in place.
 

Various stages

Image shows a part in various stages of the build process..