Fused Deposition Modeling (FDM) is, for many, the gateway to the world of 3D printing. It’s affordable, accessible, and offers a wide range of materials. But don’t think FDM is standing still! Precisely in this popular corner of the 3D printing market, we are seeing rapid developments. Let’s take a look at some of the most recent and exciting techniques elevating FDM to the next level.
1. Speed Demons: The Rise of High-Speed FDM
One of the biggest frustrations with FDM has traditionally been print speed. However, recent innovations have revolutionized this aspect:
- Klipper Firmware & Input Shaping: While Klipper has been around for a while, its adoption and refinement have been crucial for higher speeds. By offloading the computational load to a separate single-board computer (like a Raspberry Pi), Klipper can execute complex motion algorithms. Input Shaping is a key technique here: it compensates for the printer’s resonant frequencies, drastically reducing vibrations (and thus ‘ghosting’ or ‘ringing’ artifacts) at high speeds. This results in cleaner prints at speeds previously unimaginable (300mm/s to even 600mm/s+ on consumer machines).
- CoreXY and Advanced Kinematics: Printer designs using CoreXY (and to a lesser extent, Delta) motion systems are gaining traction. These systems have lighter moving masses on the print head, allowing for faster accelerations and changes in direction without sacrificing quality.
- High-Flow Hotends & Extruders: To melt and extrude enough plastic at high speeds, advanced hotends have been developed with larger melt zones and more efficient heat transfer. Direct drive extruders, often featuring planetary gear systems, offer more precise filament control, essential for rapid retractions and consistent extrusion.
- Improved Cooling: Printing faster means the molten plastic also needs to cool down faster. New printers often feature more powerful and targeted part cooling fans, sometimes even multiple, to prevent warping and deformation at high speeds.
2. Color and Material Magic: Advanced Multi-Material Systems
Printing in multiple colors or with different materials in a single object has long been complex and prone to errors. New systems are making this more accessible and reliable:
- Automatic Material Systems (AMS): Pioneers like Bambu Lab have introduced systems that automatically switch between up to four (or even sixteen via a hub) different filaments. This makes complex multi-color prints or combining, for example, PLA with soluble support material (like PVA or HIPS) much simpler. These systems often also detect filament tangles or breakages.