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Fused Filament
Fabrication Parts

Table of Contents

What is Fused Filament Fabrication?

Fused Filament Fabrication (FFF), or Fused Deposition Modeling (FDM), is a thermoplastic filament that’s melted through a heated nozzle and selectively extruded, building layer upon layer.

An industry standard, fused filament fabrication 3D printing is a process that provides engineers and designers with numerous material options with the open-source machine platform. Durable, rigid, single-color parts with moderate detail are suitable for check fixtures, specialized tools, functional prototypes, and end-use parts.

How does Fused Filament Fabrication work?

An AM Technician takes your CAD file and uploads it into the machine, where the software breaks it down layer by layer. The AM Technician also considers the direction of the build and the placement of the supports. The Fused Filament Fabrication 3D printing machines use a heated nozzle to extrude a filament onto a heated build platform. As the nozzle “draws” the part, the nozzle moves up layer by layer. This process is continual with no breaks in-between layers.

Once finished, the AM Technician removes the parts from the platform and the supports from the components. Then the parts are ready to go to the finishing department.

Fused Filament Fabrication Diagram

Ideal applications for Fused Filament Fabrication?

Since Fused Filament 3D printers use production-grade materials, it’s a suitable technology for parts throughout the product development cycle, from prototypes to end-use components. 

Form, Fit, and Concept Models

Jigs and Fixtures

Performance Testing

Complex Geometries


Fused Filament Fabrication at Midwest Prototyping



Max Build Area:

29 x 20 x 25.5 in

Lead Time:

1 – 5 Days


ABS-ESD7, ABS-M30, ASA, PC-ABS, PC-ISO, Polycarbonate (PC), Ultem 9085, Ultem 1010, and other materials may be available upon request.


± .005 in for the first inch and ± .002 in for each additional inch

Layer Thickness:

The standard layer thickness is .010 inch we can do .005, .007, and .013 inch layers as well.

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Fused Filament Fabrication materials at Midwest Prototyping



Key Characteristics

More Information

ABS-ESD7 is an ABS thermoplastic with static dissipative properties that are excellent for applications where a static charge can damage products, debilitate their performance, or cause an explosion.

  • Black
  • Impact Resistant
  • Static Dissipative
  • UV Stability

ABS-M30 has significantly stronger layer bonding than ABS and higher tensile, impact, and flexural strength. ABS-M30 parts are more durable, smoother, and have greater detail.

  • Biocompatible*
  • Impact Resistant
  • Multi-color
  • Rigid
  • UV Stability


ASA is a thermoplastic that builds high-quality parts with excellent UV stability.

  • Multi-Color
  • High Strength
  • UV Stability

PC-ABS combines the flexibility of ABS with PC’s strength and heat resistance.

  • Black or White
  • High Strength
  • Impact Resistant
  • Flexible
  • Heat Resistant

PC-ISO is strong thermoplastic, heat resistant, and biocompatible (gamma and ETO sterilizable and complies with ISO 10993 and USP Class VI standards). 

  • White
  • Biocompatible*
  • Heat Resistant
  • High Strength

Polycarbonate (PC) is a highly accurate, durable, and stable material creating strong thermoplastic parts. 

  • Biocompatible*
  • Heat Resistant
  • High Strength
  • Impact Resistant
  • Rigid
  • UV Stability

Ultem 9085 resin is a flame-retardant, high-performance thermoplastic featuring a high strength-to-weight ratio, excellent heat resistance, and high impact strength.

  • Chemical Resistant
  • Flame Retardant
  • Heat Resistant 
  • High Strength
  • Impact Resistant 
  • Rigid
  • UV Stability

Ultem 1010 resin possesses high heat resistance and thermal stability, one of the strongest thermoplastics. It is biocompatible and approved for food contact (NSF 51 and ISO 10993/USP Class VI certifications. 

  • Biocompatible*
  • High Strength
  • Heat Resistant
  • Chemical Resistant

*Special processing may be required. Please notify us of any biocompatibility needs.

Other materials may be available upon request.

Compare Materials

Designing parts for Fused Filament Fabrication at Midwest Prototyping



Supported Walls

.03 in

Unsupported Walls

.03 in

Supports & Overhangs

45 degrees

Embossing & Engraving

Width: .024 in, Height/Depth: .079 in

Horizontal Spans

.4 in

Holes & Openings

.04 in

Connecting & Moving Parts

.008 in

Escape Holes

.04 in

Minimum Features

.08 in

Pin Diameter

.04 in

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Fused Filament Fabrication finishing levels at Midwest Prototyping




Supports are removed. Parts will have visible layer lines.

Improved Exterior

Exterior (cosmetic) surfaces are sanded to reduce layer lines.

Smoothed & Sealed

Vapor smoothed and sealed for a watertight finish. May modify the geometry slightly.

Primed Exterior

Exterior (cosmetic) surfaces are smoothed to reduce layer lines and coated in grey primer.


Parts are smoothed to reduce layer lines, primed, and painted (provide drawing with paint specifications).


Custom finish. Let us know if your project requires special finishing. Please fill out our engineer-assisted quote form.

New Instant Quoting Platform!

Need a quote? We’ve got two options for you! Our instant quote provides a fast estimate, while our engineer-assisted quote offers personalized guidance. 

Instant Quoting: