Fused filament fabrication (FFF), also known as fused deposition modeling (with the trademarked acronym FDM), or filament freeform fabrication, is a 3D printing process that uses a continuous filament of a thermoplastic material. Filament is fed from a large spool through a moving, heated printer extruder head, and is deposited on the growing work. The print head is moved under computer control to define the printed shape. Usually the head moves in two dimensions to deposit one horizontal plane, or layer, at a time; the work or the print head is then moved vertically by a small amount to begin a new layer. The speed of the extruder head may also be controlled to stop and start deposition and form an interrupted plane without stringing or dribbling between sections. "Fused filament fabrication" was coined by the members of the RepRap project to give an acronym (FFF) that would be legally unconstrained in its use.
Fused filament printing is now the most popular process (by number of machines) for hobbyist-grade 3D printing. Other techniques such as photopolymerisation and powder sintering may offer better results, but they are much more costly.
The 3D printer head or 3D printer extruder is a part in material extrusion additive manufacturing responsible for raw material melting or softening and forming it into a continuous profile. A wide variety of filament materials are extruded, including thermoplastics such as acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), polyethylene terephthalate glycol (PETG), polyethylene terephthalate (PET), high-impact polystyrene (HIPS), thermoplastic polyurethane (TPU) and aliphatic polyamides (nylon).
Fused deposition modeling was developed by S. Scott Crump, co-founder of Stratasys, in 1988. With the 2009 expiration of the patent on this technology, people could use this type of printing without paying Stratasys for the right to do so, opening up commercial, DIY, and open-source (RepRap) 3D printer applications. This has led to a two-orders-of-magnitude price drop since this technology's creation.
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RepRap (a contraction of replicating rapid prototyper) is a project to develop a low-cost 3D printer that can print most of its own components. As an open design, all of the designs produced by the project are released under a free software license, the GNU General Public License. Due to the ability of the machine to make some of its own parts, authors envisioned the possibility of cheap RepRap units, enabling the manufacture of complex products without the need for extensive industrial infrastructure.
3D printing or additive manufacturing is the construction of a three-dimensional object from a CAD model or a digital 3D model. It can be done in a variety of processes in which material is deposited, joined or solidified under computer control, with material being added together (such as plastics, liquids or powder grains being fused), typically layer by layer. In the 1980s, 3D printing techniques were considered suitable only for the production of functional or aesthetic prototypes, and a more appropriate term for it at the time was rapid prototyping.
Polylactic acid, also known as poly(lactic acid) or polylactide (PLA), is a thermoplastic polyester with backbone formula (C3H4O2)n or [–C(CH3)HC(=O)O–]n, formally obtained by condensation of lactic acid C(CH3)(OH)HCOOH with loss of water (hence its name). It can also be prepared by ring-opening polymerization of lactide [–C(CH3)HC(=O)O–]2, the cyclic dimer of the basic repeating unit. PLA has become a popular material due to it being economically produced from renewable resources.
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