Additive manufacturing has transformed industrial production, offering unprecedented design freedom and efficiency. Stratasys, a leader in 3D printing, continues to drive this evolution with its advanced Fused Deposition Modeling (FDM) and PolyJet technologies. These systems enable engineers to produce highly complex parts, from functional prototypes to end-use components, across diverse industries.
FDM Industrial Printers for Robust Production
Stratasys FDM industrial printers are engineered for strength, precision, and repeatability, utilizing engineering-grade thermoplastics. Machines like the Stratasys F900 boast a large build volume of 36 x 24 x 36 inches (914.4 x 609.6 x 914.4 mm), making them suitable for substantial parts and high-throughput manufacturing. The F900, for instance, can print with layer thicknesses ranging from 0.005 inches to 0.020 inches, depending on the material.
These FDM systems are designed for demanding manufacturing needs, including jigs, fixtures, factory tooling, and functional prototypes. The F3300, a newer FDM system, incorporates linear motors and encoders for precise extruder movement and features four extruders with an automatic tool changer for multi-resolution printing. This enhances speed, throughput, and overall part quality.
Achievable accuracy for FDM parts on industrial systems like the F900 is typically within +/- 0.089 mm or +/- 0.0015 mm per mm, whichever is greater. For general FDM applications, tolerances often range from +/- 0.15 mm to +/- 0.3 mm, though this can vary with part size and printer type. Designing with adequate clearance, typically 0.4–0.6 mm for FDM, is crucial for assemblies.
PolyJet Multi-Material Printing Capabilities
| Feature | FDM Industrial Printers (e.g., F900) | PolyJet Multi-Material Printers (e.g., J35 Pro) |
|---|---|---|
| Technology | Fused Deposition Modeling (FDM) | PolyJet (Material Jetting) |
| Materials | Thermoplastics (ULTEM, Antero, PC, ABS, Nylon) | Photopolymers (Vero, Agilus30, Digital ABS Plus, Elastico) |
| Typical Accuracy | +/- 0.089 mm or +/- 0.0015 mm/mm | +/- 0.1 mm or better |
| Layer Thickness | 0.005 to 0.020 inches (0.127 to 0.508 mm) | Down to 18 microns (0.0007 inches) |
| Key Advantage | High strength, durability, large parts, production tooling | Multi-material, multi-color, fine detail, smooth surface finish |
| Applications | Functional prototypes, jigs, fixtures, end-use parts, aerospace components | Realistic prototypes, design verification, medical models, overmolding |
PolyJet technology from Stratasys offers exceptional detail resolution and the ability to print multi-material and multi-color prototypes. This process jets liquid photopolymer resins onto a build tray, which are then immediately cured by UV light. The Stratasys J35 Pro and J55 Prime are examples of office-friendly PolyJet printers, featuring rotating build platforms for superior surface finish.
PolyJet printers can combine various materials within a single print, creating parts with diverse mechanical properties and aesthetics. This includes rigid opaque, transparent, and rubber-like materials, often with over 500,000 color options on advanced systems like the J850. Digital ABS Plus, for example, simulates ABS plastics, offering strength, durability, and heat resistance for functional prototypes.
PolyJet is recognized as one of the most accurate 3D printing technologies, achieving tolerances of +/- 0.1 mm or better. This precision is vital for intricate models and parts requiring fine details, as the process does not rely on heat, reducing warpage and shrinkage. Layer thicknesses can be as fine as 18 microns (0.0007 inches) on systems like the J35 Pro.
High-Grade Additive Materials for Performance
Stratasys offers a comprehensive selection of high-performance thermoplastics and photopolymers, crucial for demanding engineering applications. For FDM, materials like ULTEM™ 9085 and ULTEM™ 1010 are flame-retardant, high-performance thermoplastics widely used in aerospace and transportation due to their strength and thermal resistance.
Antero 800NA and Antero 840CN03 are PEKK-based FDM thermoplastics known for exceptional chemical resistance, high temperature resistance, and ultra-low outgassing properties. Antero 840CN03 also features inherent electrostatic dissipative (ESD) properties, making it ideal for sensitive environments. These materials are lighter alternatives to metal alloys in some applications.
PolyJet materials include the Vero™ family for rigid opaque parts, VeroClear for transparent applications, and Agilus30™ for rubber-like flexibility. Digital Materials combine these base resins to create composite materials with customized properties, such as varying Shore A values and enhanced temperature resistance.
Production Additive Manufacturing Integration
Additive manufacturing has transitioned beyond prototyping to become a viable method for producing end-use parts in true production environments. Stratasys focuses on providing solutions that enable manufacturers to achieve medium to high volumes of qualified parts reliably and repeatedly. This shift is driven by advancements in machine capabilities, material properties, and software.
Industrial FDM systems, such as the F900, are utilized for robust production parts, jigs, fixtures, and factory tooling. Companies like Siemens Mobility have leveraged FDM to reduce manufacturing time for replacement parts by up to 95%, producing customized components on-demand. This eliminates long lead times and significant cost constraints associated with traditional tooling.
Stratasys’ approach to production additive manufacturing emphasizes flexibility, allowing parts to be produced on-demand, which reduces inventory and storage costs. The integration of software like GrabCAD Print and MTConnect readiness facilitates streamlined workflows and factory floor connectivity, supporting Industry 4.0 initiatives.
Aerospace Prototype Parts and End-Use Components
The aerospace industry heavily relies on Stratasys 3D printing for both prototyping and certified end-use parts. FDM materials like ULTEM™ 9085 and Antero™ 800NA are qualified to fly, meeting stringent aerospace standards for strength, precision, and reliability in extreme conditions.
These high-performance materials are used for applications ranging from ducting and brackets to certified aircraft components. The U.S. Air Force, for example, uses Stratasys F900 printers for certified nonstructural aircraft parts. Antero 800NA, a PEKK-based material, passes 14CFR/FAR 25.853 flame, smoke, and toxicity requirements, and MIL-STD-810G-504.1 for fluid contamination.
Stratasys Direct, a manufacturing service, is qualified to 26 material specifications and 46 process specifications for aerospace flight parts, shipping over 115,000 qualified parts per year. Their certifications include ISO 9001 and AS9100, along with ITAR registration, ensuring compliance for defense and aerospace applications.