FFF (High Grade)

Step 1

Printing

Fused Filament Fabrication utilises thermoplastic filaments that are melted as they pass through a heated nozzle. The quality of this printing process depends upon the size of the nozzle and the set layer height. The extrudate is deposited in the shape of the sliced layer geometry of the 3D CAD model. Once the layer is complete, the build platform is lowered or the print head raised by the set layer height and the process is repeated until all layers are complete.

Step 2

Support Removal

Manual Removal Supports are snapped off by hand or using pliers. Soluble Support Removal PVA or HIPS supports dissolved in water or Limonene. Note: Needle-nose pliers, cutters, or tweezers often used to remove support around finer details.

Step 3

Surface Finishing

Sanding / Polishing Used to smooth layer lines; starts with coarse grit and finishes with fine. Chemical Smoothing / Coating Acetone vapour for ABS; other materials may require specialised treatments. Painting / Priming Common for aesthetic models; requires priming before painting. Gloss / Matte Control Typically adjusted post-print via sanding, coatings, or printing at finer layer heights.

Step 4

Curing / Heat Treatment

UV / Thermal Curing Non-applicable. Annealing / Stress Relief Optional for strength improvement in a few materials like PLA or Nylon.

Step 5

Assembly and Functional Finishing

Gluing or Bonding Superglue, epoxy, or solvent welding used. Drilling / Tapping / CNC Used for precision holes or inserts; requires caution due to material brittleness. Inserts / Fasteners Threaded brass inserts or nut traps commonly added for mechanical assembly.

Step 6

Special Treatments

Infiltration / Sealing Epoxy or resin coating used to strengthen or waterproof. Functional Coatings Paint, rubberising sprays or metalising for aesthetics and protection. Post-print Functionalisation Embedding magnets, sensors or electronics into multi-part prints.