Material Extrusion Lab

Material Extrusion (ME)

Stacker S4

345x520x650 mm (13.6×20.5×25.6 in) build volume
4 extruders for multi-material parts
Open architecture

re:3D Gigabot X

565x593x470 mm (22.2×23.3×18.5 in) build volume
Prints from pellets and flakes
Ability to print from recycled materials
On loan from re:3D for research

AON M2+

450x450x565 mm (17.7×17.7×22.2 in) build volume
Dual 500 degree C extruders
Ability to print high temperature materials such as PEEK, PEKK, and ULTEM
Build chamber heating to 135 degrees C

What is Material Extrusion?

Material extrusion goes by several names including fused deposition modelling (FDM), fused filament fabrication (FFF), and fused granular fabrication (FGF). The basic principle for polymer material extrusion is to melt polymer feedstock and extrude it through a nozzle onto a build platform. The feedstock can be in the form of filament strands that are wound around a spool or granulated pellets that are fed to the extruder via a hopper. The liquid polymer cools as it exits the nozzle and solidifies, allowing the material to be selectively deposited. The cross section of the part is traced by the extruder for a given layer, and the process is repeated by lowering the build platform.

ME Advantages

Wide range of material options
Hollow internal cavities are possible
Low waste

ME Considerations

Support structures are required for overhangs that exceed 45 degrees
Layers tend to be pronounced, causing rough external surfaces
Feature sizes should be on the order of 1.0 mm for the best results
Avoid printing large flat plates parallel to the build plate to avoid excessive warping