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Proceedings of CAD'15, 2015, 502-507
Fused Deposition Modelling Design Rules for Building Large, Complex Components

J. Urbanic, University of Windsor
R. Hedrick, CAMufacturing Solutions Inc., Ontario, Canada

Abstract. The Fused Deposition Modeling (FDM) process is a bead deposition process which builds a product from thin layers of molten thermoplastic filaments (i.e., acrylonitrile butadiene styrene (ABS), polycarbonates, polycaprolactone, polyphenylsulfones, and waxes). The wire is fed through a temperature-controlled head and the material extruded when it is in a semi-viscous state. The resulting bead is elliptical in shape. The head is mounted on an x-y positioning system. The table is mounted on the z axis, which is indexed one layer thickness lower after each layer is deposited. The extrusion head has two outlets, one for the component material, and the other for the support material. The support material is required for overhanging features such as holes orthogonal to the build direction. The component and support materials are deposited in separate operations per layer. The beads for the perimeter and fill for the build material are deposited, and then the support material is extruded as appropriate. The support material must be removed afterwards. Depending on the feature location and the support material properties, this can be a time consuming process.

Keywords. Rapid Prototyping, Fused Deposition Modelling, Design Rules, Process Limitations, Rapid Tooling

DOI: 10.14733/cadconfP.2015.502-507