The technology that reaches the largest parts and the most certified materials. Five Stratasys systems in house — including a Fortus 900 that prints ULTEM at nearly a metre.
FDM is the best-known 3D printing process, but at industrial level it is a different thing entirely from a desktop machine. Thermoplastic filament is heated and laid down layer by layer inside a sealed, temperature-controlled chamber — and that is what makes it possible to print in genuine engineering materials and get a dimensionally stable part.
The real advantage of FDM is certified materials combined with size. No other process lets you print a part nearly a metre across in a material that carries aerospace documentation.
How FDM works
A heated print head pulls thermoplastic filament from a spool, melts it and lays it along a precise path on the build platform. The layer cools and solidifies, the platform drops, and the head lays the next layer on top. A second head lays support material under overhanging geometry — material that later dissolves in water or peels away.
All of this happens inside a sealed, heated chamber. That is the core difference between an industrial machine and a desktop one: uniform temperature prevents shrinkage and warping, and makes it possible to run materials like ULTEM that need high temperatures.
What matters at the design stage
An FDM part is stronger along the layers than between them. Build orientation therefore changes the strength of the part, and on load-bearing parts we discuss orientation before printing. In powder processes such as MJF this problem barely exists.
The systems we run
| System | Why we use it |
|---|---|
| Fortus 900 | Very large parts and ULTEM for aerospace. Build volume up to 914 × 610 × 914 mm — the largest in the category. |
| F3300 | A newer generation of FDM — large parts at production throughput |
| F770 | Especially long parts in ASA and ABS |
| Fortus 450 | The widest material range, including ULTEM and Nylon CF |
| F370-CR | Carbon-fibre reinforced materials, simple operation |
FDM materials
| Material | Character | Typical use |
|---|---|---|
| ULTEM 9085 | High temperature resistance, flame retardant, high strength-to-weight | Aircraft interiors, defence systems, demanding end-use parts |
| ULTEM 1010 | The most temperature resistant, food-contact approved | Tooling for heat processes, autoclave |
| PC / PC-ISO | Polycarbonate — rigid and impact resistant | Housings, tooling, medical applications (PC-ISO) |
| ABS / ABS-M30i | Engineering ABS, with a biocompatible grade | Functional prototypes and end-use products |
| ASA | UV and weather resistance | Parts used outdoors |
| Nylon CF | Carbon-fibre reinforced nylon | High stiffness at low weight — production fixtures |
| ABS-ESD7 | Static dissipative | Electronics and discharge-sensitive components |
| PA6/66-GF30-FR | Glass filled and flame retardant | Applications that must meet a fire standard |
Full technical data and manufacturer datasheets for every grade are on our FDM materials pages.
When FDM is the right choice
- ULTEM or an aerospace-certified material is required — there is no substitute for this in our other technologies
- A large part — up to nearly a metre in one dimension, in one piece rather than split and bonded
- High temperature resistance
- Production fixtures and tooling
- One or two units — where filling a powder build chamber would not pay
And when something else is better
- Series of tens and up — MJF is usually faster and cheaper per part
- Uniform strength in every direction — an FDM part is weaker between layers; powder processes are close to isotropic
- Complex geometry needing heavy support — SLS and MJF need none at all
- Fine detail or a very smooth surface — resin or PolyJet
Accuracy, finish and what to expect
The tolerances we work to on FDM:
| Axis | Tolerance |
|---|---|
| X / Y | ±0.3% (minimum ±0.3 mm) |
| Z | ±0.5% (minimum ±0.5 mm) |
Achievable accuracy also depends on part size, geometry and orientation, so we confirm tolerances against your drawing before printing rather than promising a blanket figure. Our full published figures are in our terms. Where one feature needs a tighter tolerance, we print with excess stock and machine it on a CNC.
An FDM surface shows visible layer lines — more so than powder processes. It can be smoothed, sanded, painted or coated where appearance matters.
Frequently asked questions
What is ULTEM, and why is it in such demand?
ULTEM is a high-performance thermoplastic (PEI) that combines high temperature resistance, flame retardancy and a high strength-to-weight ratio, and it carries the documentation aerospace work requires. That combination is why it is specified for aircraft interiors and demanding defence applications — and why FDM is the only one of our processes that can print it.
How strong is an FDM part?
In engineering materials, strong enough for end use — these are the same polymers used in injection moulding. The caveat is direction: the bond between layers is the weak point, so a part is stronger along the layers than across them. Tell us how the part is loaded and we will orient it accordingly.
What is the maximum size you can print?
914 × 610 × 914 mm on the Fortus 900 — nearly a metre in one dimension, and the largest in the category. Beyond that a part can be split and bonded.
Do supports have to be removed by hand?
Not usually. Our systems print soluble support material that dissolves in a bath, which is what allows internal channels and enclosed geometry. Some materials use a break-away support that peels off instead.
How long does it take?
FDM is slower per part than the powder processes, and a large part can run for a day or more, followed by support removal and finishing. Actual lead time depends on current load — tell us your deadline and we will tell you honestly whether it is achievable.
Have a file? We will tell you whether FDM is the right choice
Send a STEP or STL and we will come back with a recommendation on technology, material and price for the quantity you need — including if the answer is that another process suits you better. If you need to meet an aerospace or fire standard, tell us up front.
Indus3D is an additive manufacturing bureau in Israel, an approved supplier to the Israeli Ministry of Defense, AS9100D and ISO 9001 certified. We run a range of printing technologies under one roof and support projects from file to finished part.