3D Printing Service:
Fused Filament Fabrication

Parts in 1 to 5 days.
Additive Manufacturing Nozzle-Based Technology | Fused Filament Fabrication (FFF)

Fused Filament Fabrication (FFF) is used for:

Quality Matters  |  AS9100D Certified, ISO 9001:2015, ISO 13485:2016, & ITAR Registered

Certifications and Registrations

* Not all locations have all certifications and registrations. Parts requiring these will be made at facilities with the correct certifications and registrations.

Additive Manufacturing Nozzle-Based Technology | Fused Filament Fabrication (FFF)
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.

Fused FIlament Fabrication part capabilities

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.

AM Technology | Fused Filament Fabrication (FFF)

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:

Disadvantages to Fused Filament Fabrication

While there are a lot of advantages to fused filament fabrication, there are also some disadvantages to consider:

Fused Filament Fabrication at Prototek

Fused Filament Fabrication Machine Company:

Stratasys

Fused Filament Fabrication File Types:

Preferred Files: Solid, STEP, and DFX

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

Fused Filament Fabrication (FFF) - ABS-ESD7
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

Fused Filament Fabrication (FFF) - ABS-M30
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

Fused Filament Fabrication (FFF) - ASA
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

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

Fused Filament Fabrication (FFF) - PC-ISO

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

Fused Filament Fabrication (FFF) - Polycarbonate (PC)
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

Fused Filament Fabrication (FFF) - Ultem 1010
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

Fused Filament Fabrication (FFF) - Ultem 9085
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.

Prototek's Additive Design Poster
Feature Measurement

Connecting & Moving Parts

0.008 in

Escape Holes

0.04 in

Embossing & Engraving

Width: 0.024 in
Height/Depth: 0.08 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
Height/Depth: 2 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?

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.

What do our customers say about us?
They are competitively priced for their services and a very personable team to work with. If you haven't used them - do it! You'll have a lifelong vendor you be happy with that repeatedly goes above and beyond what is asked.
Product Designer
Great design input to ensure the prototype build went smoothly. The parts look phenomenal and function better than we had anticipated.
Outdoor Sports Industry

Standard Drill Bit Sizes

Drill Size

Imperial

Metric

#107

0.0019 in

0.0483 mm

0.05 mm

0.0020 in

0.0500 mm

#106

0.0023 in

0.0584 mm

#105

0.0027 in

0.0686 mm

#104

0.0031 in

0.0787 mm

#103

0.0035 in

0.0889 mm

#102

0.0039 in

0.0991 mm

0.1 mm

0.0039 in

0.1000 mm

#101

0.0043 in

0.1092 mm

#100

0.0047 in

0.1194 mm

#99

0.0051 in

0.1295 mm

#98

0.0055 in

0.1397 mm

#97

0.0059 in

0.1499 mm

#96

0.0063 in

0.1600 mm

#95

0.0067 in

0.1702 mm

#94

0.0071 in

0.1803 mm

#93

0.0075 in

0.1905 mm

0.2 mm

0.0079 in

0.2000 mm

#92

0.0079 in

0.2007 mm

#91

0.0083 in

0.2108 mm

#90

0.0087 in

0.2210 mm

#89

0.0091 in

0.2311 mm

#88

0.0095 in

0.2413 mm

#87

0.0100 in

0.2540 mm

#86

0.0105 in

0.2667 mm

#85

0.0110 in

0.2794 mm

#84

0.0115 in

0.2921 mm

0.3 mm

0.0118 in

0.3000 mm

#83

0.0120 in

0.3048 mm

#82

0.0125 in

0.3175 mm

#81

0.0130 in

0.3302 mm

#80

0.0135 in

0.3429 mm

#79

0.0145 in

0.3680 mm

1/64 in

0.0156 in

0.3969 mm

0.4 mm

0.0158 in

0.4000 mm

#78

0.0160 in

0.4064 mm

#77

0.0180 in

0.4572 mm

0.5 mm

0.0197 in

0.5000 mm

#76

0.0200 in

0.5080 mm

#75

0.0210 in

0.5334 mm

#74

0.0225 in

0.5715 mm

0.6 mm

0.0236 in

0.6000 mm

#73

0.0240 in

0.6069 mm

#72

0.0250 in

0.6350 mm

#71

0.0260 in

0.6604 mm

0.7 mm

0.0276 in

0.7000 mm

#70

0.0280 in

0.7112 mm

#69

0.0292 in

0.7417 mm

#68

0.0310 in

0.7874 mm

1/32 in

0.0313 in

0.7938 mm

0.8 mm

0.0315 in

0.8000 mm

#67

0.0320 in

0.8128 mm

#66

0.0330 in

0.8382 mm

#65

0.0350 in

0.8890 mm

0.9 mm

0.0354 in

0.9000 mm

#64

0.0360 in

0.9144 mm

#63

0.0370 in

0.9398 mm

#62

0.0380 in

0.9652 mm

#61

0.0390 in

0.9906 mm

1 mm

0.0394 in

1.0000 mm

#60

0.0400 in

1.0160 mm

#59

0.0410 in

1.0414 mm

#58

0.0420 in

1.0668 mm

#57

0.0430 in

1.0922 mm

1.1 mm

0.0433 in

1.1000 mm

#56

0.0465 in

1.1811 mm

3/64 in

0.0469 in

1.1906 mm

1.2 mm

0.0472 in

1.2000 mm

1.3 mm

0.0512 in

1.3000 mm

#55

0.0520 in

1.3208 mm

#54

0.0550 in

1.3970 mm

1.4 mm

0.0551 in

1.4000 mm

1.5 mm

0.0591 in

1.5000 mm

#53

0.0595 in

1.5113 mm

1/16 in

0.0625 in

1.5875 mm

1.6 mm

0.0630 in

1.6000 mm

#52

0.0635 in

1.6129 mm

1.7 mm

0.0669 in

1.7000 mm

#51

0.0670 in

1.7018 mm

#50

0.0700 in

1.7780 mm

1.8 mm

0.0709 in

1.8000 mm

#49

0.0730 in

1.8542 mm

1.9 mm

0.0748 in

1.9000 mm

#48

0.0760 in

1.9304 mm

5/64 in

0.0781 in

1.9844 mm

#47

0.0785 in

1.9939 mm

2 mm

0.0787 in

2.0000 mm

#46

0.0810 in

2.0574 mm

#45

0.0820 in

2.0828 mm

2.1 mm

0.0827 in

2.1000 mm

#44

0.0860 in

2.1844 mm

2.2 mm

0.0866 in

2.2000 mm

#43

0.0890 in

2.2606 mm

2.3 mm

0.0906 in

2.3000 mm

#42

0.0935 in

2.3749 mm

3/32 in

0.0938 in

2.3813 mm

2.4 mm

0.0945 in

2.4000 mm

#41

0.0960 in

2.4384 mm

#40

0.0980 in

2.4892 mm

2.5 mm

0.0984 in

2.5000 mm

#39

0.0995 in

2.5273 mm

#38

0.1015 in

2.5781 mm

2.6 mm

0.1024 in

2.6000 mm

#37

0.1040 in

2.6416 mm

2.7 mm

0.1063 in

2.7000 mm

#36

0.1065 in

2.7051 mm

7/64 in

0.1094 in

2.7781 mm

#35

0.1100 in

2.7940 mm

2.8 mm

0.1102 in

2.8000 mm

#34

0.1110 in

2.8194 mm

#33

0.1130 in

2.8702 mm

2.9 mm

0.1142 in

2.9000 mm

#32 

0.1160 in

2.9464 mm

3 mm

0.1181 in

3.0000 mm

3.1 mm

0.1221 in

3.1000 mm

1/8 in

0.1250 in

3.1750 mm

3.2 mm

0.1260 in

3.2000 mm

#30

0.1285 in

3.2639 mm

3.3 mm

0.1299 in

3.3000 mm

3.4 mm

0.1339 in

3.4000 mm

#29

0.1360 in

3.4544 mm

9/64 in

0.1406 in

3.5719 mm

5/32 in

0.1563 in

3.9688 mm

11/64 in

0.1719 in

4.3656 mm

3/16 in

0.1875 in

4.7625 mm

13/64 in

0.2031 in

5.1594 mm

7/32 in

0.2188 in

5.5563 mm

15/64 in

0.2344 in

5.9531 mm

1/4 in

0.2500 in

6.3500 mm

17/64 in

0.2656 in

6.7469 mm

9/32 in

0.2813 in

7.1438 mm

19/64 in

0.2969 in

7.5406 mm

5/16 in

0.3125 in

7.9375 mm

21/64 in

0.3281 in

8.3344 mm

11/32 in

0.3438 in

8.7313 mm

23/64 in

0.3594 in

9.1281 mm

3/8 in

0.3750 in

9.5250 mm

25/64 in

0.3906 in

9.9219 mm

13/32 in

0.4063 in

10.3188 mm

27/64 in

0.4219 in

10.7156 mm

7/16 in

0.4375 in

11.1125 mm

29/64 in

0.4531 in

11.5094 mm

15/32 in

0.4688 in

11.9063 mm

31/64 in

0.4844 in

12.3031 mm

1/2 in

0.5 in

12.700 mm

33/64 in

0.5156 in

13.0969 mm

17/32 in

0.5313 in

13.4938 mm

35/64 in

0.5469 in

13.8906 mm

9/16 in

0.5625 in

14.2875 mm

37/64 in

0.5781 in

14.6844 mm

19/32 in

0.5938 in

15.0813 mm

39/64 in

0.6094 in

15.4781 mm

5/8 in

0.6250 in

15.8750 mm

41/64 in

0.6406 in

16.2719 mm

43/64 in

0.6719 in

17.0656 mm

11/16 in

0.6875 in

17.4625 mm

45/64 in

0.7031 in

17.8594 mm

23/32 in

0.7188 in

18.2563 mm

47/64 in

0.7344 in

18.6531 mm

3/4 in

0.7500 in

19.0500 mm

49/64 in

0.7656 in

19.4469 mm

25/32 in

0.7813 in

19.8438 mm

51/64 in

0.7969 in

20.2406 mm

13/16 in

0.8125 in

20.6375 mm

53/64 in

0.8281 in

21.0344 mm

27/32 in

0.8438 in

21.4313 mm

55/64 in

0.8594 in

21.8281 mm

7/8 in

0.8750 in

22.2250 mm

57/64 in

0.8906 in

22.6219 mm

29/32 in

0.9063 in

23.0188 mm

21/23 in

0.9130 in

23.1913 mm

59/64 in

0.9219 in

23.4156 mm

15/16 in

0.9375 in

23.8125 mm

61/64 in

0.9531 in

24.2094 mm

31/32 in

0.9688 in

24.6063 mm

63/64 in

0.9844 in

25.0031 mm

1 in

1.0000 in

25.4000 mm

1 1/64 in

1.0156 in

25.7969 mm

1 1/32 in

1.0313 in

26.1938 mm

1 3/64 in

1.0469 in

26.5906 mm

1 1/16 in

1.0625 in

26.9875 mm

1 5/64 in

1.0781 in

27.3844 mm

1 3/32 in

1.0938 in

27.7813 mm

1 7/64 in

1.1094 in

28.1781 mm

1 1/8 in

1.1250 in

28.5750 mm

1 9/64 in

1.1406 in

28.9719 mm

1 5/32 in

1.1563 in

29.3688 mm

1 11/64 in

1.1719 in

29.7656 mm

1 3/16 in

1.1875 in

30.1625 mm

1 13/64 in

1.2031 in

30.5594 mm

1 7/32 in

1.2188 in

30.9563 mm

1 15/64 in

1.2344 in

31.3531 mm

1 1/4 in

1.2500 in

31.7500 mm

1 17/64 in

1.2656 in

32.1469 mm

1 9/32 in

1.2813 in

32.5438 mm

1 19/64 in

1.2969 in

32.9406 mm

1 5/16 in

1.3125 in

33.3375 mm

1 21/64 in

1.3281 in

33.7344 mm

1 11/32 in

1.3438 in

34.1313 mm

1 23/64 in

1.3594 in

34.5281 mm

1 3/8 in

1.3750 in

34.9250 mm

1 25/64 in

1.3906 in

35.3219 mm

1 13/32 in

1.4063 in

35.7188 mm

1 27/64 in

1.4219 in

36.1156 mm

1 7/16 in

1.4375 in

36.5125 mm

1 29/64 in

1.4531 in

36.9094 mm

1 15/32 in

1.4688 in

37.3063 mm

1 31/64 in

1.4844 in

37.7031 mm

1 1/2 in

1.5000 in

38.1000 mm