Everything you need to know about how FDM 3D printing works, what materials we stock, and which one is right for your application. Not sure? We're happy to advise.
Fused Deposition Modelling (FDM) — sometimes called Fused Filament Fabrication (FFF) — is the most widely used additive manufacturing process in industry. A thermoplastic filament is fed into a heated nozzle, melted, and deposited layer by layer onto a build plate to build up a three-dimensional part directly from a digital file.
Unlike subtractive manufacturing (where material is cut away), FDM adds material only where it's needed. This means minimal waste, the ability to produce highly complex internal geometries, and no tooling costs — making it particularly cost-effective for one-off and small batch production.
Modern industrial FDM systems print with engineering-grade thermoplastics capable of matching or exceeding the performance of many injection-moulded parts — with the added advantage of being available in days rather than weeks, and without minimum order requirements.
At FormStrata Ltd, every part is produced on enclosed, temperature-controlled industrial-grade hardware, using dried, quality-verified filament. Print parameters are optimised per material and application — not set-and-forget defaults.
Digital model
A 3D CAD file (STL, STEP, or OBJ) is sliced into thin horizontal layers using specialist software. Print parameters — layer height, infill, supports, temperature — are set per material.
Filament preparation
Hygroscopic materials (Nylon, PC, PPS-CF) are dried before printing to remove moisture that would compromise layer adhesion and surface quality.
Layer-by-layer deposition
The printhead deposits molten material along precisely calculated paths. Each layer bonds to the one below as it cools, building the part from the base up.
Support removal
Where overhangs require temporary support structures, these are removed post-print — either manually or dissolved, depending on the material.
Post-processing & inspection
Parts are inspected dimensionally and checked against the original specification before dispatch. Every part is reviewed before it leaves us.
Jigs & fixtures
Custom assembly aids, alignment tools, and drill guides produced on demand — faster and cheaper than machined equivalents for low-volume production lines.
End-use components
Brackets, housings, mounts, and functional enclosures for automation equipment, conveyors, robotics, and control systems.
Spare & legacy parts
Replacement components for equipment no longer in production — reverse engineered and reproduced to spec, eliminating long lead times and obsolescence risk.
Prototyping
Functional prototypes for fit, form, and functional testing before committing to tooling — in the actual material intended for end use.
Tooling & moulds
Short-run injection mould inserts, casting patterns, and forming tools for low-volume production runs where hard tooling isn't cost-justified.
Automotive & transport
Interior components, cable management, sensor housings, and custom brackets — particularly for specialist, heritage, and commercial vehicle applications.
Food & pharmaceutical
Conveyor guides, product handling components, and equipment modifications in PETG and food-contact-grade materials where hygiene is a priority.
Electronics & control
Custom enclosures, cable management, DIN rail adaptors, and sensor mounts — designed and printed to exact dimensions, not adapted from off-the-shelf parts.
We stock a range of materials from general-purpose thermoplastics through to high-performance engineering composites. The right material depends on your application — mechanical loads, temperature exposure, chemical environment, and whether the part is a prototype or end-use component. If you're unsure, we'll advise.
PLA
Polylactic Acid
A plant-derived thermoplastic and the most widely used FDM material. Easy to print, dimensionally accurate, and available in a wide range of colours. Best suited for non-structural, low-temperature applications.
Real-world uses
PETG
Polyethylene Terephthalate Glycol
A step up from PLA in toughness and temperature resistance, with good chemical resistance and moisture tolerance. PETG is food-contact safe and widely used in industrial and consumer applications requiring durability.
Real-world uses
TPU
Thermoplastic Polyurethane
A flexible, rubber-like material with excellent abrasion and impact resistance. TPU is the go-to choice wherever a printed part needs to flex, compress, or cushion — without breaking.
Real-world uses
PETG-CF / PETG-GF
Carbon & Glass Fibre Reinforced PETG
PETG reinforced with chopped carbon or glass fibre delivers significantly improved stiffness and strength while retaining the ease of printing and chemical resistance of standard PETG. A practical step up for structural applications.
Real-world uses
ABS
Acrylonitrile Butadiene Styrene
An established engineering thermoplastic with good impact resistance, machinability, and higher temperature tolerance than PLA or PETG. Well-suited to functional enclosures and parts that require post-processing such as tapping, drilling, or bonding.
Real-world uses
ASA
Acrylonitrile Styrene Acrylate
Functionally similar to ABS but with significantly better UV and weathering resistance. The preferred choice for parts intended for outdoor or exposed environments where ABS would degrade over time.
Real-world uses
Nylon PA6
Polyamide 6
A tough, fatigue-resistant engineering nylon with excellent wear properties and a low coefficient of friction. PA6 is hygroscopic and requires controlled printing conditions to achieve consistent mechanical performance.
Real-world uses
Nylon PA6-CF / PA6-GF
Carbon & Glass Fibre Reinforced Polyamide 6
Carbon or glass fibre reinforcement transforms PA6 into a high-stiffness structural composite with metal-comparable specific strength. Widely used in aerospace, automotive, and industrial applications where weight and rigidity both matter.
Real-world uses
PC
Polycarbonate
One of the strongest and most impact-resistant thermoplastics available for FDM printing. Polycarbonate maintains its properties at elevated temperatures and is well suited to demanding structural and protective applications.
Real-world uses
PPS-CF
Carbon Fibre Reinforced Polyphenylene Sulfide
One of the most chemically and thermally resistant materials available for FDM. PPS-CF offers metal-like rigidity, inherent flame retardance (UL94 V0 rated), and exceptional resistance to acids, alkalis, and organic solvents. The material of choice for demanding chemical and high-heat environments.
Real-world uses
PPA-CF
Carbon Fibre Reinforced Polyphthalamide
A high-performance nylon composite reinforced with 15% chopped carbon fibre. PPA-CF delivers exceptional strength, stiffness, and thermal resistance, with significantly lower moisture absorption than standard nylons — making it more dimensionally stable in humid or variable environments. It outperforms PA6-CF on thermal resistance while remaining easier to print than PPS-CF.
Real-world uses
Tell us about your application and we'll recommend the most appropriate option — and quote accordingly.