FDM (Fused Deposition Modeling) and FFF (Fused Filament Fabrication) are terms used to describe the same 3D printing process. These methods create objects by melting plastic filament and extruding it through a nozzle. The printer lays down thin layers of the material, building the object layer by layer.
So, what’s the difference?
- FDM, or Fused Deposition Modeling, is a trademark of Stratasys, the company that invented the process in the late 1980s.
- FFF, or Fused Filament Fabrication, was coined by the open-source RepRap community in 2005 to avoid legal issues.
Most people use the terms interchangeably, and unless you’re buying a Stratasys machine, it really doesn’t matter which one you choose to say.
The Role of the RepRap Movement
We can thank the RepRap movement for making 3D printing accessible. The open-source project launched in 2005 to develop open-source 3D printers that could print their parts, making 3D printing technology cost-effective and cheaper.
RepRap played a significant role in popularizing 3D printing for personal and hobbyist use. It also inspired the development of many commercial 3D printers that expanded on RepRap designs and firmware.
The RepRap movement gave hobbyists and small businesses access to what was previously an expensive, exclusive technology. The name “FFF” emerged from this community, allowing the additive technology to spread without legal hurdles.
How FDM and FFF Work
Whether you call it FDM or FFF, the process is identical: heating thermoplastic filament, extruding it through a nozzle, and depositing it layer by layer to build a 3D object.
The printer’s nozzle melts the plastic filament while moving precisely across the print area. After printing the first layer, the nozzle rises to build upon the previous level.
As the melted filament is deposited, it cools and solidifies almost immediately, often with the help of cooling fans. Strong bonding between layers depends on correct temperatures, consistent extrusion, and controlled cooling.
The process is simple enough for hobbyists to produce beautiful objects with minimal cost and research.
But here’s the catch: parts made with this method often have visible layer lines and are weak where the layers join. Many prints benefit from taking additional steps like removing supports or smoothing rough edges to achieve a finished product.
Materials Used in FDM/FFF
Countless materials are used in 3D printing, and there are too many to include in this article. Selecting the right material for your application can make or break your print. Different materials offer trade-offs between ease of use, cost, strength, durability, UV resistance, heat resistance, and color, to name a few.
Here are some of the most common 3D printing materials.
- PLA is the most popular filament used by hobbyists and beginners. It’s easy to print, eco-friendly, cheap, and available in a wide range of colors. It also offers the best print quality. PLA filament has a low melting point and isn’t suitable for outdoor use.
- ABS filament is complex to print but more durable and heat-resistant, making it better for functional parts. However, it gives off potentially hazardous and unpleasant fumes when printing and experience is required to achieve good print quality.
- PETG filament is a solid middle ground between PLA and ABS, offering strength, flexibility, and good print quality while reasonably easy to print.
- Nylon filament is durable and flexible but requires a lot of experience and trial and error to achieve good prints.
- Polycarbonate (PC) filament is extremely strong and heat-resistant, perfect for high-stress parts. However, you’ll need a premium printer to print at the high temperatures required for PC filament.
If you’re working on industrial projects, high-performance plastics like ULTEM or PEEK are also options—though they’ll require specialized equipment and patience.
Use Cases for FDM/FFF
FDM and FFF 3D printing are versatile tools that cater to a wide range of needs. The technology is simple enough for hobbyists yet powerful enough for professional workflows.
Its speed, affordability, and accessibility make it an ideal choice for various applications:
- Prototyping: FFF and FDM 3D printing allow product designers to quickly turn their drawings into a physical product. Designers can test product fit, functions, and designs in a fraction of the time of traditional prototyping. Producing multiple prototypes through FFF printing is quicker and costs a fraction of the price, allowing for rapid design iterations.
- Custom Parts: One of the most practical uses of FDM/FFF printing is creating custom or replacement parts. Whether it’s a missing piece for a machine, a personalized component for a project, or even a discontinued item, the ability to design and print on demand is invaluable. I’ve fixed dozens of broken items around my house by printing custom parts.
- Educational Projects: Schools and universities use FDM/FFF printers to teach students about design, engineering, architecture, and technology. FDM 3D printing allows students to learn 3D modeling, material science, and manufacturing by creating a fun and practical application. This hands-on approach helps bridge theoretical knowledge with practical application, making it a popular choice in STEM education.
- Hobbyist Creations: Hobbyists love FDM/FFF printers for their flexibility and ease of use. These machines empower makers to craft various objects, including cosplay props, action figures, tools, household items, and even drones. The only fundamental limitation is your imagination.
- Art and Design: Artists and designers use FDM/FFF printing to produce sculptures, jewelry prototypes, and other creative works. The ability to experiment with shapes, colors, and textures makes it an excellent tool for exploring new ideas.
- Customized Products: FDM/FFF printing allows businesses to sell personalized products at scale, unlike traditional manufacturing, which requires expensive injection molds. 3D printing allows businesses to create one-off custom pieces like custom phone cases, ergonomic tools, or personalized gifts.
