Fused Deposition Modelling (FDM) is one of the most widely adopted additive manufacturing technologies in the world, particularly for functional prototyping and end-use part production. Parts produced via FDM exhibit excellent mechanical strength, chemical resistance and thermal stability and are widely used across aerospace, defence, automotive, medical and industrial sectors where repeatability, material performance and reliability are critical.
Evolution of the FDM Process
The technology was invented in the late 1980s by Stratasys co-founder Scott Crump, who developed the concept of extruding thermoplastic filament through a heated nozzle to build parts layer by layer. This invention formed the basis of modern filament-based additive manufacturing and established Stratasys as a pioneer in the field. Since its commercialisation in the early 1990s, Stratasys has continuously refined the technology, transforming FDM from a prototyping tool into a robust manufacturing solution capable of producing highly functional, production-grade components.
The FDM Process
In FDM printing, thermoplastic filament is fed into a heated extrusion head, melted, and deposited in precise toolpaths onto a build platform. Each deposited layer solidifies and bonds to the previous layer, gradually forming the final three-dimensional object. The process is digitally driven, enabling complex geometries to be manufactured directly from CAD files without the need for tooling. Stratasys systems integrate advanced motion control, closed-loop temperature management, and sophisticated slicing algorithms to ensure consistent layer adhesion and dimensional accuracy.
Advantages of Stratasys FDM Systems
While filament-based 3D printing is now widely available, industrial FDM systems from Stratasys offer several key advantages that differentiate them from lower-cost alternatives.
Precision and Repeatability
Industrial Stratasys printers are engineered for production environments where dimensional accuracy and repeatability are critical. Controlled thermal environments and precision motion systems minimise warping and ensure consistent part quality across multiple builds.
Engineering-Grade Materials
Stratasys offers an extensive portfolio of validated thermoplastics, including engineering polymers such as ABS, ASA, polycarbonate, nylon, and high-performance materials like ULTEM™ and PEKK. These materials provide excellent mechanical strength, chemical resistance, and thermal stability, allowing parts to be used in demanding industrial environments.
Soluble Support Technology
One of the defining features of Stratasys FDM systems is their soluble support materials. Complex geometries, internal channels, and intricate features can be printed using sacrificial support structures that are later dissolved in a chemical bath. This enables the production of highly complex parts that would otherwise be impossible to manufacture using traditional machining.
Industrial Reliability
Stratasys systems are designed for continuous operation in engineering and manufacturing environments. Automated calibration, material handling systems, and robust hardware design ensure dependable performance and reduced operator intervention.
GrabCAD Environment
GrabCAD is integrated into all Stratasys 3D printers. It is a highly evolved, user-friendly interface that streamlines instrument control and simplifies printing operations.
It provides a comprehensive print preparation and job management platform that facilitates:
- Import CAD files directly (STEP, STL, etc.)
- Automatic part orientation and tray layout
- Support material management
- Print job scheduling and monitoring
- Remote printer control
Scaling Up Production
When it comes to scaling up production, Stratasys are best placed to assist you with their range of industrial 3D printers, designed for high throughput applications. If you have been using a printing service like AXT who use Stratasys systems, or if you have outgrown your existing Stratasys system, Stratasys solutions are the natural progression. Similarly, if you have been using a system from another manufacturer, Stratasys are likely to have a higher capacity machine to suit your needs.
Material Diversity and Functional Performance
One of the defining strengths of Stratasys FDM technology is its broad portfolio of thermoplastic materials. These include polymers designed for mechanical strength, chemical resistance, flame retardancy and high-temperature operation.
Examples include:
- ABS and ASA for durable prototypes and outdoor applications
- Nylon 12 for impact-resistant parts and functional testing
- Polycarbonate (PC) for high-strength engineering components
- ULTEM™ 9085 and ULTEM™ 1010 for aerospace-grade applications requiring flame, smoke and toxicity compliance
- ESD-safe materials for electronics manufacturing environments
Because these materials behave similarly to injection-moulded thermoplastics, FDM parts can often be used directly in functional assemblies.
Key Applications of FDM 3D Printing
FDM technology is widely adopted for both rapid prototyping and functional manufacturing applications.
Common applications include:
- Functional prototyping and design validation
- Aerospace interior components and certified aircraft parts
- Manufacturing jigs, fixtures and tooling
- Automotive prototyping and production aids
- Defence and field-deployable spare parts
- Medical device development and surgical planning models
- Custom housings and enclosures for electronics
- Low-volume production of complex polymer components
- Replacement parts for legacy equipment
- Research and development in advanced materials
Because parts can be produced directly from digital designs, organisations can significantly reduce lead times, inventory costs and supply chain risks.
Industrial Stratasys FDM Solutions from AXT
AXT supplies and supports Stratasys additive manufacturing systems throughout Australia and New Zealand. By combining Stratasys’ industry-leading technology with local technical expertise, AXT helps organisations adopt additive manufacturing for prototyping, tooling and production by supplying Stratasys systems or providing 3D printing services using Stratasys systems installed in our Sydney facility.
Whether used to accelerate product development, improve manufacturing efficiency or produce end-use parts, Stratasys FDM systems deliver reliable, repeatable and scalable industrial 3D printing.
Stratasys FDM 3D Printers
