Fused Filament Fabrication OR FFF 3D Printing


One of the most affordable and widely used 3D Printing technology in the market as of date. This particular technology uses filament strands or wires as the raw material. The wire is heated, and extruded through a nozzle tracing the path of the model.


1. PLA

2. ABS

3. PET-G

4. Wood-Fill

5. Nylon – Carbon Fiber


Key Attributes

Key Takeaways

• Affordable
• Rapid Turnaround
• Fitment Prototypes

Limitations –

  • Tolerances are high +-0.5mm.
  • Anisotropic in nature (weak in the z direction).
  • Overhangs tend to generate rough surfaces.
  • Layers are visible.

Ideally Used For

  • Prototyping
  • Architectural Models
  • Electronic Casings
  • Batch Production

Post Processing

  • Priming
  • Sanding
  • Painting

Design Guidelines



Wall Thickness –

1. Minimum Wall Thickness – 1.2mm

2. For decent strength (Recommended Thickness) – 2.5mm



Minimum Feature Size – 1.2mm




 Overhang Structures –

1. To prevent overhang structures from falling Support Structures are generated

2. Ideally the Surface between the lower Overhand Structure and Upper Support Structure tend to be Rough



 Crisp Gradient

1. Angle With Horizontal Should be > 50 Degrees

2. This is Done to Avoid Support Material Generation as mentioned above



 Shaft Diameters –

1. Recommended Shaft Diameter = 3mm

2. If Part is Small, Printing Multiple Parts is Recommended to Allow Part Cooling





1. Concept of Bridging is used where Overhang Structure has 2 Pillars to Support it

2. Maximum Gap Between Pillars = 50mm

3. This Avoids Support Material Generation, Saving on Material & Printing Time.



Hole Diameters

1. Minimum Hole Diameter = 2.5mm

2. Minimum Gap Between Holes = 2mm

3. Holes tend to Shrink Due to Material Properties

Ideal Shrinkage is 0.3mm to 0.4mm



Letter Engraving –

1. Letter Depth – 0.8mm

2. Letter Width – 0.8mm