§ 01 / WHEN

When FDM is the right choice

FDM wins when one of three things is true: budget, speed, or size.

For budget: FDM parts cost roughly 30–50% of equivalent SLA or SLS parts. If you need 10 variants of a bracket to visualize ergonomics, FDM is the only sensible technology.

For speed: FDM parts ship in 2–3 days. Complex geometries don't meaningfully change this. Compared to SLS (5–7 days) and DMLS (7–14 days), it's faster.

For size: our large-format FDM printers handle single-piece parts up to 400 × 400 × 400 mm. Larger than what most SLA and SLS printers can produce without splitting and gluing.

FDM is not the right choice when: the part needs cosmetic-grade surface finish (visible layer lines disqualify it); the part has small features below 1 mm (FDM resolution is coarse); the part will see significant loads or temperatures (FDM parts are anisotropic — weaker along the layer axis); or the part needs to be watertight (FDM parts have micro-porosity between layers).

§ 02 / MATERIALS

Materials we stock for FDM

Material	Best for	Tensile strength	HDT	Cost factor
PLA	Concept models, visual prototypes	50 MPa	55 °C	1.0×
PETG	Functional prototypes, moderate heat	50 MPa	70 °C	1.1×
ABS	Impact-resistant, machinable	40 MPa	98 °C	1.2×
ASA	UV-resistant outdoor parts	45 MPa	95 °C	1.3×
Nylon (PA)	Wear parts, living hinges	55 MPa	95 °C	1.8×
TPU 95A	Flexible gaskets, grips	25 MPa	80 °C	1.7×
PC-ABS	Tough, heat-resistant prototypes	55 MPa	115 °C	2.0×
PEEK	Aerospace, medical	95 MPa	260 °C	12×

Cost factor is relative to PLA on the same geometry. PEEK requires a specialist high-temp printer and is 10–15× more expensive per gram.

§ 03 / TYPICAL

Typical applications

Concept modelsLow-cost form studies — especially for consumer products, packaging, industrial design.

Ergonomic mockupsHandles, controllers, wearables. Print 5 variants, pick one, iterate.

Jigs & fixturesAssembly guides, drill templates, alignment jigs — printed in PETG or PLA.

Architectural modelsScale mockups, massing studies, presentation pieces.

Enclosures & housingsElectronics housings where the part hides inside a product and cosmetics don't matter.

Replacement partsObsolete hardware, custom brackets, shims — anything not cost-effective to machine.

§ 04 / DESIGN

Design guidelines for FDM

Wall thickness ≥ 1.2 mm

At least 3 perimeters of 0.4 mm nozzle extrusion. Below 1.2 mm, walls become gappy or ripply.

Minimum feature size: 0.8 mm

Text, embossed logos, thin ribs — anything below 0.8 mm will either fail to print or print mushy.

Overhangs above 45° need support

FDM can't print into free air. Overhangs above 45° from vertical need support material, which leaves marks on the removed surface.

Holes shrink — design oversize

Horizontal holes print smaller than designed. Add 0.2–0.3 mm to the diameter, or drill to size post-print.

Orient for load direction

FDM parts are 30–50% weaker between layers than within a layer. If the part will see bending loads, tell us the load direction so we orient the print accordingly.

§ 05 / FREQUENTLY

Frequently asked

Can you print in a custom color?

Yes — we stock PLA and PETG in 12 common colors. Pantone-specific matching is possible with a $35 setup fee and 2-day delay to source filament.

How strong are FDM parts versus injection molded?

FDM parts are 30–50% weaker in tensile strength than injection-molded equivalents in the same resin, due to layer-to-layer bonding. In compression they're nearly equal. Design for compression or continuous fiber direction when possible.

Can I get a smooth cosmetic finish on FDM?

Post-process options include vapor-smoothing (ABS in acetone), sanding and priming, or epoxy coating. All add cost and time. For cosmetic parts, SLA is almost always a better choice.

What file formats do you accept?

STL is standard. STEP accepted — we convert in-house. OBJ, 3MF, IGES all fine. Include a PDF drawing if critical dimensions need to be verified post-print.

FDM 3D printing — the fastest path to a part in hand.