FDM 3D Printing
Fast and affordable parts in a variety of materials for prototyping and production
What is FDM 3D Printing?
FDM is a versatile 3D printing technology that builds parts one layer at a time by extruding heated thermoplastics through a nozzle. Known for its affordability and quality, FDM is ideal for low-volume production of both prototypes and functional parts. Work with materials like PLA, ABS, TPU, PETG, and PEI to cover a wide range of applications.
Why Companies Choose FDM 3D Printing at Protolabs
Faster Than In-House Printing
Avoid print queues, machine downtime, and failed builds. Access scalable capacity to run multiple parts and larger builds at once without slowing down development.
Functional Parts Without the Hassle
No printer setup, tuning, monitoring, or reprints are required. Upload your design and receive ready-to-use parts without managing your own equipment or materials.
Cost-Effective Components
FDM is an affordable way to produce thermoplastic parts, reducing cost for iteration, testing, and production tooling—without added printers or internal resources.
Scale Instantly When Demand Increases
Easily handle greater quantities and larger builds without upfront capital investment. Increase output without adding more machines or tying up your internal team.
Choose the Right FDM Process for Your Application
Prototyping FDM
- Fast, affordable functional parts
- Ideal for prototypes, jigs, fixtures, and tools
- Available materials include: PLA, PETG, ASA, ABS, and TPU
- Optimized for speed and cost
Industrial FDM
- Production-grade performance and durability
- Ideal for end-use components and high-spec applications
- Available materials include: ULTEM and reinforced nylons
- Built for repeatability and long-term use
FDM Design Guidelines and Capabilities
Our basic guidelines for FDM include important design considerations to help improve part precision and reduce overall production time.
| US | Metric | ||
|---|---|---|---|
| Max Part Size | Prototyping FDM | Up to 19.68 in. x 19.68 in. x 19.68 in. | Up to 500mm x 500mm x 500mm |
| Industrial FDM | Up to 15.98 in. x 13.97 in. x 15.98 in. | Up to 406mm x 355mm x 406mm | |
| Dimensional Accuracy | Prototyping FDM | ± 0.5% with a lower limit of ±0.020 in. | 0.5mm |
| Industrial FDM | ± 0.3% with a lower limit of ±0.012 in. | ±0.3mm | |
| Unsupported/Supported Walls | Minimum 0.0315 in. | Minimum 0.8mm | |
| Minimum Feature Size | 0.0787 in. | 2.0mm | |
| Minimum Hole Diameter | 0.0787 in. | 2.0mm | |
| Layer Height Options | from 100-300 μm | ||
| Infill Options | Light to solid to suit strength requirements |
FDM Material Options
| Protolabs FDM materials for prototyping are typically chosen for their ease of use, speed, and cost-effectiveness, focusing on enabling rapid design iterations and validation. Materials for production are selected for their durability, specific mechanical properties, and long-term performance, ensuring they meet standards for end-use applications. |
FDM Materials for Prototyping:
Industrial FDM Materials:
PLA (Polylactic Acid)
expand_less expand_moreKnown for excellent surface finish and ease of printing, PLA is biodegradable and ideal for visual models and consumer products
PETG (Polyethylene Terephthalate Glycol)
expand_less expand_moreOffers a good combination of strength and flexibility, making it food-safe and suitable for mechanical parts
ASA (Acrylonitrile Styrene Acrylate)
expand_less expand_moreProvides UV resistance and weatherability, perfect for outdoor applications
ABS (Acrylonitrile Butadiene Styrene)
expand_less expand_moreKnown for impact resistance and strength, suitable for durable prototypes and functional parts
TPU (Thermoplastic Polyurethane)
expand_less expand_moreHighly flexible and abrasion-resistant, ideal for creating rubber-like components
Nylon (Markforged Onyx)
expand_less expand_moreOffers superior tensile strength and toughness, ideal for functional prototypes and production parts requiring durability and wear resistance
ULTEM (Stratasys)
expand_less expand_moreULTEM 9085 and ULTEM 1010: Known for high thermal and chemical resistance, suitable for aerospace and automotive applications where high performance is critical
ASA (Stratasys)
expand_less expand_moreCombines good mechanical properties with UV stability, perfect for robust outdoor and automotive components
ABS (Stratasys)
expand_less expand_moreABS M30 and ABSplus: Provides enhanced strength and stability, suitable for end-use parts needing reliable performance under stress
Common Applications for FDM 3D Printing
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How Does FDM 3D Printing Work?
Fused Deposition Modeling (FDM) creates parts by heating and extruding thermoplastic filaments layer by layer, resulting in solid objects with practical functionality.
Unlike resin-based technologies such as stereolithography (SLA)—which use liquid photopolymers cured by a UV laser to achieve fine details and smooth finishes—FDM offers the advantage of lower costs and faster production times.
Additionally, although powder-based methods such as selective laser sintering (SLS) fuse material powders into complex shapes without the need for support structures, FDM remains a versatile and economical option for producing durable parts, especially when surface finish is not the primary concern. This makes FDM ideal for functional prototypes and low-volume manufacturing across a range of industries.