3D Printing Service:
Fused Filament Fabrication
Parts in 1 to 5 days.
Fused Filament Fabrication (FFF) is used for:
- Biocompatible Materials
- High-Performance Components
- Cost Efficient Prototyping
Quality Matters | AS9100D Certified, ISO 9001:2015, ISO 13485:2016, & ITAR Registered
* Not all locations have all certifications and registrations. Parts requiring these will be made at facilities with the correct certifications and registrations.
Our Digital Manufacturing Process is Simple.
Upload a CAD file and request a quote.
Our team starts production after finalizing project specifications and accepting the quote with you.
When the part has been completed and finished, it passes through quality control.
After your part goes through quality control, our team ships the part(s) to you.
What is Fused Filament Fabrication?
Fused filament fabrication (FFF) is a 3D printing process that uses a thermoplastic filament fed through a heated extruder head and deposited in layers to create a three-dimensional object. This additive manufacturing technique allows for the production of complex geometries and customized parts, making it a popular choice for rapid prototyping, small-batch production, and plastic part customization across various industries.
How does Fused Filament Fabrication work?
In our Fused Filament Fabrication (FFF) process, customers create and submit a 3D model of the object they need using Computer-Aided Design (CAD) software. Once we receive the CAD file, we use slicing software to prepare the model for printing. This step involves dividing the model into thin layers and generating a set of instructions for the printer to follow. These instructions include details such as the temperature at which the filament should be melted, the speed at which it should be extruded, and the position of the nozzle.
Subsequently, the printer feeds the filament and softens it using a heated nozzle or extruder. The melted plastic is then extruded and quickly solidified to form a layer. The printer repeats this process for each layer until the object is complete. Finally, the object is removed and ready for finishing and post-processing.
Advantages to Fused Filament Fabrication
Fused filament fabrication technology has revolutionized the way products are designed and manufactured. The following are a few of the advantages of fused filament fabrication:
- Very fast.
- Great for large simple parts.
- Variety of materials and colors.
Disadvantages to Fused Filament Fabrication
While there are a lot of advantages to fused filament fabrication, there are also some disadvantages to consider:
- Rough surfaces.
- Low resolution, printing quality not ideal for small features or tiny parts.
- Support structures are necessary.
Fused Filament Fabrication at Prototek
Fused Filament Fabrication Machine Company:
Stratasys
Fused Filament Fabrication File Types:
Max Build Chamber Size:
36 x 24 x 36 in
Lead Time:
1 – 5 Days
Material:
ABS-ESD7, ABS-M30, ASA, Nylon 12CF, PC-ISO, Polycarbonate (PC), Ultem 9085, Ultem 1010, and other materials may be available upon request.
Tolerances:
± 0.005 in for the first inch and ± 0.002 in/in for each additional inch.
Layer Thickness:
The standard layer thickness is 0.010 inch. We can do 0.005, 0.007, and 0.013-inch layers as well.
Prototek's Materials
ABS-ESD7
This material is a blend of ABS polymer and a conductive substance, such as carbon nanotubes, carbon fibers, conductive carbon black, or Graphene NanoPlatelets. Additionally, it protects against ESD, making it ideal for manufacturing and packaging electronic devices.
Tensile Strength
5,200 psi
Tensile Modulus
350 ksi
Elongation @ Break
3%
Flexural Strength
8,800 psi
Flexural Modulus
350 ksi
Heat Deflection @ 264 psi
180° F
ABS-M30
ABS-M30 comprises ABS and an additive that enhances strength and toughness. It produces functional prototypes, end-use parts, and low-volume production runs. ABS-M30 has excellent dimensional stability, high tensile strength, and abrasion resistance.
Tensile Strength
4,650 psi
Tensile Modulus
320 ksi
Elongation @ Break
7%
Flexural Strength
8,700 psi
Flexural Modulus
300 ksi
Heat Deflection @ 264 psi
180° F
ASA
ASA boasts exceptional durability, ensuring it can withstand prolonged sun exposure and high temperatures without damage or degradation.
Tensile Strength
4,750 psi
Tensile Modulus
290 ksi
Elongation @ Break
9%
Flexural Strength
8,700 psi
Flexural Modulus
270 ksi
Heat Deflection @ 264 psi
196° F
Nylon 12CF
Nylon 12CF combines Nylon 12 with chopped carbon fiber to achieve exceptional flexural strength and stiffness-to-weight ratio. Consequently, it is regarded as one of the best FDM materials available.
Tensile Strength
12,100(250) psi
Tensile Modulus
1,370(67) ksi
Elongation @ Break
2.4(0.29)%
Flexural Strength
22,200(310) psi
Flexural Modulus
1,610(40) ksi
Heat Deflection @ 264 psi
265.7° F
PC-ISO has been specifically formulated to meet the stringent safety standards of ISO 10993-1. Therefore, it is ideal for medical devices, surgical instruments, and implants. Furthermore, its biocompatibility and durability make it a reliable and long-lasting option for these critical applications.
Tensile Strength
8,300 psi
Tensile Modulus
289.8 ksi
Elongation @ Break
4%
Flexural Strength
13,100 psi
Flexural Modulus
310.4 ksi
Heat Deflection @ 264 psi
260° F
Polycarbonate (PC)
Polycarbonate (PC) is a transparent, impact-resistant, lightweight thermoplastic polymer commonly used in electronic components, automotive parts, construction materials, and eyewear.
Tensile Strength
8,300 psi
Tensile Modulus
282 ksi
Elongation @ Break
4.8%
Flexural Strength
13,000 psi
Flexural Modulus
291 ksi
Heat Deflection @ 264 psi
261° F
ULTEM 1010
ULTEM 1010 is a high-strength, amorphous thermoplastic made from polyetherimide (PEI) resin. It is known for its exceptional thermal, chemical, and impact resistance, which makes it ideal for various applications.
Tensile Strength
N/A
Tensile Modulus
440(25) ksi
Elongation @ Break
4.0(0.4)%
Flexural Strength
18,475(570) ksi
Flexural Modulus
420(7) ksi
Heat Deflection @ 264 psi
410° F
ULTEM 9085
ULTEM 9085 is a high-performance thermoplastic material used in various industries, such as aerospace, automotive, and medical. Furthermore, it is lightweight and robust and has seasonal mechanical and thermal properties, making it ideal for applications requiring high strength and heat resistance.
Tensile Strength
10,000(145) psi
Tensile Modulus
365(9) ksi
Elongation @ Break
5.4(0.5)%
Flexural Strength
14,740(140) psi
Flexural Modulus
348(5) ksi
Heat Deflection @ 264 psi
343° F
*Special processing may be required. Please notify us of any biocompatibility needs.
Design Recomendations
When designing parts for Fused Filament Fabrication 3D printing, consider the orientation, wall thickness, overhangs, support structures, and material selection. Choose the correct orientation and avoid thin walls to achieve a consistent, vital part. Use features such as fillets, chamfers, or draft angles to reduce overhangs. Complex designs require support structures, placed with consideration for functionality and post-printing finishing. The material selection affects the characteristics of the final product, such as strength, durability, and flexibility.
| Feature | Measurement | |
|---|---|---|
|
|
Connecting & Moving Parts |
0.008 in |
|
|
Escape Holes |
0.04 in |
|
|
Embossing & Engraving |
Width: 0.024 in |
|
|
Holes & Openings |
0.04 in |
|
|
Horizontal Spans |
0.4 in |
|
|
Minimum Features |
0.08 in |
|
|
Pin Diameter |
0.04 in |
|
|
Supports & Overhangs |
45° |
|
|
Walls (Supported) |
0.03 in |
|
|
Walls (Unsupported) |
0.03 in |
| Feature | Measurement | |
|---|---|---|
|
|
Connecting & Moving Parts |
0.2 mm |
|
|
Escape Holes |
1 mm |
|
|
Embossing & Engraving |
Width: 0.6 mm |
|
|
Holes & Openings |
1 mm |
|
|
Horizontal Spans |
10 mm |
|
|
Minimum Features |
2 mm |
|
|
Pin Diameter |
1 mm |
|
|
Supports & Overhangs |
45° |
|
|
Walls (Supported) |
0.8 mm |
|
|
Walls (Unsupported) |
0.8 mm |
Fused Filament Fabrication Finishes
Prototek Digital Manufacturing is pleased to offer a diverse selection of high-quality finishes using fused filament fabrication (FFF) that can be customized to meet your precise requirements. Our advanced FFF 3D printers ensure that we consistently produce superior, durable, and accurate printed parts with unmatched reliability, guaranteeing your satisfaction at every stage of the process.
Fused Filament Fabrication Finishes
| Level | Process |
|---|---|
|
Natural |
Supports are removed. Parts will have visible layer lines. |
|
Improved Exterior |
Exterior (cosmetic) surfaces are sanded to reduce layer lines. |
|
Smoothed & Sealed |
Vapor smoothed and sealed for a watertight finish. May modify the geometry slightly. |
|
Primed Exterior |
Exterior (cosmetic) surfaces are smoothed to reduce layer lines and coated in grey primer. |
|
Painted |
Parts are smoothed to reduce layer lines, primed, and painted (provide drawing with paint specifications). |
|
Custom |
Custom finish. Let us know if your project requires special finishing. Please fill out our engineer-assisted quote form. |
Learn More About FFF
Through our resources, you can discover the complexities of FFF 3D printing technology and gain insights into creating top-notch designs specifically tailored for this cutting-edge technology.
A comparison of AM nozzle-based technologies fused filament fabrication and material jetting. Which is better for your project?
Prototek's
Other Additive Manufacturing Technologies
Why choose Prototek for your next fused filament fabrication project?
Prototek, a leading 3D printing service provider, is dedicated to providing the best quality products with their Fused Filament Fabrication (FFF) technology. Additionally, they use state-of-the-art equipment and quality materials to ensure precision and high-quality manufacturing of durable and reliable parts. Moreover, what sets Prototek apart is its unmatched team of skilled technicians who strive to deliver customized solutions catered to each client’s specific needs. Furthermore, they pride themselves on their competitive pricing while not sacrificing production quality. Ultimately, when you choose Prototek, you’re not just getting a superior quality product, but you’re also getting a reliable partner dedicated to your every need.
