Manufacturing services · Chapter F · Method 32

FDM / FFF printing

Core TCI route

Thermoplastic filament is melted and laid down bead by bead, layer by layer. Quick and inexpensive for jigs, formers and concept models.

Ask about this method All 3D printing methods

FDM printer in the TCI workshop. TCI workshop

FDM print head laying down a part. Representative process photo · Jakub Zerdzicki · Pexels

How it works

FDM / FFF printing, step by step.

A labelled schematic of the process (not to scale), and the four steps every job goes through.

Labelled diagram showing how fdm / fff printing works — Schematic · not to scale. Drawn by TCI Group.

STEP 01

Slice

Slice the model into layers and paths.

STEP 02

Extrude

A heated nozzle lays down molten filament.

STEP 03

Layer

The bed or head steps up one layer at a time.

STEP 04

Finish

Remove supports; sand or seal if needed.

Reference figures

What to expect.

Typical industry values to help you plan. We agree the figures for your part on the drawing.

Tolerance± one layer + 0.002 mm/mmTypical

Layer0.20–0.33 mmDesktop to industrial

FinishRa 6.4–22.9 µmAs printed

Min Feature~1 mmRaised features

Materials	PLA, PETG, ABS, ASA, nylon, TPU, PC and carbon-filled grades.
Finishes	Visible layer lines; sanded, primed and painted or vapour smoothed.
Design guidance	Orient for strength; layers are weakest in Z. Use heat-set inserts rather than printed threads. Holes under 1 mm and horizontal holes print oval.
Best suited to	Mould boxes, pour formers, jigs, fixtures and early concept models.
Watch-outs	Anisotropic strength and visible layers; not ideal as a master for fine silicone detail.

Other methods in 3D printing

Previous: Metal injection moulding (MIM)Next: Selective laser sintering (SLS)

Next step

Not sure this is the right route?

Send a sketch, photo, sample or CAD file with your quantity and target date. We will recommend the most sensible route and explain the trade-offs before quoting.

Start an enquiry

Reference figures are typical published industry values for planning, not a guarantee; final tolerances, materials and finishes are agreed in writing for each project.