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Here's What is New in the FDM Composite Tooling Design Guide 2.0 

aaron pearson
Aaron Pearson March 24, 2020
March 24, 2020
fdm design guide

In May, 2016, we launched the inaugural FDM composite tooling design guide. The goal was to build a base of knowledge to educate and enable the readers to confidently design, build, and use additively manufactured composite tooling. Due to the overwhelming positive response to this design guide, we are excited to announce the 2nd edition titled “FDM for Composite Tooling Design Guide 2.0.”

So what’s new in Design Guide 2.0?


Updated Best Practices:

Although there are many ways to approach the various challenges that can arise when designing tools for composite fabrication, the updated design guide includes recommendations for many of the common scenarios we have encountered to help ensure your success. Specifically, the guide includes updated best practices for:

    • Scribe lines


    • Tool repair


    • Incorporating localized reinforcement for inserts


    • Near-net-shape tooling (Machining FDM tools)


    • Multi-section tools

More Data:

Design Guide 2.0 includes test data for ULTEM™ 1010 resin at critical cure temperatures as well as empirical data for pressure resistance of the new hexagram fill pattern. The hexagram fill pattern, Figure 1, has shown the potential to reduce material use by 200% compared to the more traditional sparse double dense fill pattern.

Screen Shot 2017 10 19 at 3 52 08 PM

Figure 1 – Views of the Insight-generated fill patterns, hexagram (left) and sparse double dense (right).

New Case Studies:

Design Guide 2.0 includes new customer case studies from Dassault Falcon Jet, Rock West Composites and Team Penske to illustrate how different industries are leveraging FDM technology to ease the manufacturing and procurement process, allow for rapid response to customer needs, and accelerate innovation.

The FDM Composite Tooling Design Guide 2.0 offers a wealth of new information to help users be successful. Head over to the Stratasys website to download the new version of the guide and get all the latest information and case studies.


ULTEM™ is a registered trademark of SABIC or its affiliates.