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FDM, particularly industrial FDM like running on a Stratasys Fortus, will be the best plastic 3D printing process to mitigate warping. I recommend exploring materials like ASA and polycarbonate for large, broad, flat parts. Avoid "warpy" plastics like nylon or ULTEM unless absolutely necessary.

FDM is better than SLS or MJF because the parts are built attached to a flat build plate. SLS and MJF do not have any supporting structures so broad parts can twist or flex during cooling. The sacrifice is in detail resolution. Maybe you could explore a hybrid approach in your design or splitting and assembling to achieve your results.

[Arnaud]

Hello, what is the best 3D printing process for creating large flat parts that is less prone to warping? This has been a significant concern in initial tests with FDM, especially around the edges. I am also looking for a finer printing resolution, around 0.1 mm per layer if possible. Would a process like SLS or MJF be better suited for this type of application? Or are there other techniques or material combinations that might help maintain the flatness and precision at this scale?

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[Greg Paulsen]

FDM, particularly industrial FDM like running on a Stratasys Fortus, will be the best plastic 3D printing process to mitigate warping. I recommend exploring materials like ASA and polycarbonate for large, broad, flat parts. Avoid “warpy” plastics like nylon or ULTEM unless absolutely necessary.

FDM is better than SLS or MJF because the parts are built attached to a flat build plate. SLS and MJF do not have any supporting structures so broad parts can twist or flex during cooling. The sacrifice is in detail resolution. Maybe you could explore a hybrid approach in your design or splitting and assembling to achieve your results.

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[Arnaud]

Thanks, Greg! That’s super helpful. Appreciate the insights!

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