Fused Deposition Modeling (FDM)

Fused Deposition Modeling (FDM), also known as Fused Filament Fabrication (FFF), is the most common type of additive manufacturing. FDM has short lead times, a relatively low cost per part, and can produce larger parts than many other additive polymer technologies. Thanks to a variety of material choices and finishing options, FDM is ideal for creating everything from quick prototypes to the final product. Our in-house FDM technologies include the Fortus 450mc and the Stratasys F900.

Producing parts with FDM

General process information

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Max. part size	• 914 x 610 x 914 mm • 36.0 x 24.0 x 36.0 in
min. feature size	0.4 mm • 0.016 in
LEAD TIME	• Get your parts in as little as three business days.

NEED HELP WITH YOUR DESIGN? Materials

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Ultem 1010	PC-ISO	ABS-ESD7	PPSF	Nylon 12
Ultem 9085	PC-ABS	ABS-M30i	ST-130	Nylon 12 CF
PC-10	ASA	ABS-M30	Nylon 6	Antero 800NA

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FINISHING/POST-PROCESSING OPTIONS	col 2 Row1	col 3 Row1	col 4 Row1
Painting	Sanding	Heat staked inserts	Epoxy impregnation
Bead blasting	Vapor smoothing	Press-fit inserts

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Common FDM Applications

Thanks to a variety of material choices and finishing options, FDM is ideal for creating everything from quick prototypes to the final product. Regulatory requirements Aerospace, food-grade and automotive applications. Large parts Larger build size than other additive technologies. Jigs and fixtures Practical and reliable tooling. Prototypes Quick turnaround allows for rapid iteration.

FDM resources

Learn more about the FDM services we offer at the Fast Radius resource center. The difference between industrial-grade FFF and desktop 3D printers READ MORE Choosing the best rapid prototyping process READ MORE Five tips to help you design for additive manufacturing READ MORE VIEW ALL RESOURCES

Carbon Digital Light Synthesis (DLS)

Carbon DLS is a resin-based polymer process that uses light and heat to create parts with isotropic properties, complex geometries, and excellent surface finishes. DLS offers a wide range of production-grade materials, allowing engineers to build end-use parts right off the printer. Fast Radius’ Chicago factory is the largest public install-base of Carbon technology in North America.

Producing parts with Carbon DLS

General process information

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Max. part size	• 189 x 118 x 326 mm • 7.4 x 4.6 x 12.8 in
min. feature size	Material dependent, typically: • ~0.25 - 0.5 mm • ~0.01 - 0.02 in
LEAD TIME	• Get your parts in as little as three business days.

NEED HELP WITH YOUR DESIGN? Materials

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Elastomeric Polyurethane - EPU 40 and EPU 41	Multi-purpose Polyurethane - MPU 100	Silicone - SIL 30	Whip Mix
Rigid Polyurethane - RPU 70 and RPU 130	Epoxy - EPX 82	Cyanate Ester - CE 221	Urethane Methacrylate - UMA 90

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FINISHING/POST-PROCESSING OPTIONS	col 2 Row1	col 3 Row1	col 4 Row1
Painting	Smoothing	Press-fit inserts	Hydrographics
Bead blasting	Heat staked inserts	Digital texturing	Laser surface decorating/etching

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Common Carbon DLS Applications

DLS is often used for end-use parts because it produces high tolerances and smooth surface finishes. The speed of the DLS process makes it attractive for rapid prototyping as well. High-volume production runs Cost-effective and quick production of small parts. Functional prototyping Durable prototypes suitable for testing in real-world conditions. Complex parts Process allows geometries that would be impossible with other methods. Foam replacement Elastomeric lattice design enables custom mechanical responses. Chemical and heat resistant parts Materials that meet many functional and regulatory requirements.

Carbon DLS resources

Learn more about the Carbon DLS services we offer at the Fast Radius resource center. 4 applications you should produce with additive manufacturing READ MORE Product design with compliant lattices: 6 key considerations READ MORE Beyond prototyping: Scaling up to additive manufacturing for production READ MORE VIEW ALL RESOURCES

HP Multi Jet Fusion (MJF)

HP MJF is a powder bed fusion process that creates strong parts with high dimensional accuracy. Because MJF doesn’t require support structures, the process allows more design freedom than many other additive processes. Fast Radius is a member of HP’s Digital Manufacturing Network, meaning our production facility meets HP’s highest standards for quality.  Our factory houses two HP Jet Fusion technologies: 4200 3D Printing Solutions, which are known for creating durable parts that meet many regulatory requirements; and the HP Jet Fusion 580, which uses the same technology to print parts in full color.

Producing parts with HP MJF

HP Jet Fusion 4200 General process information

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Max. part size	• 375 x 375 x 280 mm • 14.8 x 14.8 x 11.0 in
min. feature size	• 0.5 mm • 0.02 in
LEAD TIME	• Get your parts in as little as four business days for Nylon PA 12 and five business days for 40% Glass Bead Filled Nylon PA 12.

HP Jet Fusion 580 Color General process information

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Max. part size	• 332 x 190 x 248 mm • 13.1 x 7.5 x 9.8 in
min. feature size	• 0.5 mm • 0.02 in
LEAD TIME	• Get your parts in as little as four business days with a color file provided and as little as five business days without a color file provided.

NEED HELP WITH YOUR DESIGN? HP Jet Fusion 4200 Materials

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Nylon PA 12

40% Glass Bead Filled Nylon PA 12

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FINISHING/POST-PROCESSING OPTIONS	col 2 Row1	col 3 Row1	col 4 Row1
Painting	Bead blasting	Press-fit inserts	Smoothing
Black dyeing	Heat staked inserts	Digital texturing	Laser surface decorating/etching

HP Jet Fusion 580 Color Materials

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CB Nylon PA 12 - accepts all CMYK values

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FINISHING/POST-PROCESSING OPTIONS	col 2 Row1	col 3 Row1
Heat staked inserts	Press-fit inserts	Bead blasting

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Every day we’re working with the world’s leading product manufactuers to make the parts that matter most to their businesses. View Full Case Study

Common HP MJF Applications

MJF parts have high tensile strength and sufficient resolution for many end-use applications. Complex assemblies Consolidate several parts into one. Functional prototyping Durable prototypes suitable for testing in real-world conditions. Chemical-resistant parts Resistance to oils, greases, aliphatic hydrocarbons, and alkalies. Housings, fixtures, tooling, connectors Ideal for applications requiring high stiffness.

HP MJF resources

Learn more about the HP MJF services we offer at the Fast Radius resource center. What to expect during the additive manufacturing process READ MORE Rethinking part consolidation with additive manufacturing READ MORE 4 applications you should produce with additive manufacturing READ MORE VIEW ALL RESOURCES

Stereolithography (SLA)

SLA is a type of photopolymerization capable of producing parts with an excellent surface finish and small feature resolution. SLA parts have low tensile strength and low UV resistance, making it unsuitable for most high-performance applications.

Producing parts with SLA

Materials

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Accura 25	Accura 60	Somos® NeXT	Somos® ProtoGen 1840
Accura Xtreme	Accura ABS Black	Somos® PerFORM	Somos® WaterShed XC 11122

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FINISHING/POST-PROCESSING OPTIONS	col 2 Row1
Sanding	Polishing
Metal coating	Paint

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Common SLA Applications

SLA produces parts with small feature resolution and excellent surface finish, making it a good technology for applications where details are important. Master patterns High dimensional accuracy for precise patterns. Scale models Capable of producing intricate details with high-resolution. Prototypes Excellent resolution, small feature size, and finish.

SLA advantages and challenges

ADVANTAGES

• Intricate and accurate detailing
• Specialty materials
• No finishing necessary

CHALLENGES

• Limited tensile strength
• Requires temporary supports
• Light sensitivity

SLA resources

Learn more about the SLA services we offer at the Fast Radius resource center. Choosing the best rapid prototyping process READ MORE Should I use CNC machining or 3D printing to create my master pattern? READ MORE Quick reference guide to additive technology READ MORE VIEW ALL RESOURCES

PolyJet

PolyJet 3D printing technology can produce detailed parts with complex geometry in a matter of hours, which makes it ideal for applications requiring speed and detail. PolyJet is often used for prototypes since it produces parts with high resolution but low strength.

Producing parts with PolyJet

Materials

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VeroWhitePlus	Digital ABS RGD5160-DM	VeroBlue
VeroGray	VeroClear	FullCure RGD720
RGD450	PolyJet Flex & Over-Mold	PolyJet TangoPlus

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FINISHING/POST-PROCESSING OPTIONS	col 2 Row1	col 3 Row1
Glass bead blasting	Paint	UV resistant coating

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Common PolYJet Applications

Rapid prototyping Print and test design iterations quickly. Multimaterial parts Parts with different mechanical and aesthetic qualities. Concept models Intricate details, high-resolution, and vibrant colors. Color-coded parts Produce multiple colors in a single process.

PolyJet advantages and challenges

ADVANTAGES

• Wide variety of materials
• Complex geometries
• Rapid production
• Water soluble supports

CHALLENGES

• Limited tensile strength
• Limited build size
• UV sensitivity
• Relatively high cost

Polyjet resources

Learn more about the PolyJet services we offer at the Fast Radius resource center. VIEW ALL RESOURCES

Selective Laser Sintering (SLS)

SLS is a powder bed fusion technology that produces parts with high dimensional accuracy and isotropic mechanical properties while also allowing for considerable design freedom.

Producing parts with SLS

Materials

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Flex TPE	Nylon 11 FR	Nylon 12 PA	Nylon 12 GF	Nylon 12 GSL	Nylon 12 AF
Nylon 11 EX	Nylon 11	Nylon 12 FR	Nylon 12 CF	Nylon 12 HST

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FINISHING/POST-PROCESSING OPTIONS	col 2 Row1
Waterproof coating	Media polishing
Painting	Dyeing

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Common SLs Applications

SLS is capable of producing parts with fine detail and isotropic mechanical properties. SLS offers materials with high heat and chemical resistance, making it suited for harsh industrial environments. Chemical resistance Variety of chemical-resistant polymers available. Rapid prototyping Print and test design iterations quickly. Ducts Complex interior features, high tensile strength, and heat resistance.

SLs advantages and challenges

ADVANTAGES

• No support structures needed
• Internal no-access features
• High dimensional accuracy
• Isotropic mechanical properties

CHALLENGES

• Rough texture
• Porous structure
• Relatively slow printing speed

SLS resources

Learn more about the SLS services we offer at the Fast Radius resource center. VIEW ALL RESOURCES