Fused Deposition Modeling of Metals
Abstract
Studies have been conducted to improve previous work performed in developing a Fused
Deposition Modeling for metals (FDMm) system used for applications in electronics and
fabrication of 3-dimensional metallic structures. A FDM 3000 system was modified to achieve
controlled deposition of eutectic Bi58Sn42 and non-eutectic Sn60Bi40 materials. Toolpath
command modifications were required to achieve controlled deposition of metals. Results are
presented which include a redesigned metal deposition head, computer modeling of fluid flow,
and finally examples of the successful deposition of metal alloys. Additionally, FDMm-fabricated metal samples were prepared and analyzed using optical and scanning electron
microscopy. Controlled deposition of metals using FDMm allows for parts that can be used for
jigs and fixtures, electroforming mandrels, encapsulation molds, dies, electronic joining
applications, as well as printing 3-dimensional electronic circuitry.