FAST PROTO TYPES

 FDM (Fused Deposition Modeling) and SLA (Stereolithography) are the two most common rapid prototyping technologies, but they serve somewhat different purposes.


Quick Comparison

FDM process

Melted plastic filament deposited layer by layer


SLA process

UV laser cures liquid resin layer by layer

_________

Typical Materials for FDA

PLA, ABS, PETG, Nylon, PC

for SLA

Photopolymer resins

________

Accuracy

FDA.   ±0.2 to ±0.5 mm

SLA±0.05 to ±0.2 mm

_________

Surface Finish

FDA.    Visible layer lines

SLA.     Very smooth

_______

Fine Details

 FDA.    Moderate

SLA.      Excellent

________

Mechanical Strength

FDA. Generally better for functional parts

SLA.   Often more brittle

_____________

Build Speed

FDA.   Moderate to fast

SLA.     Moderate

____________


Material Cost

FDA.     Lower

SLA.      Higher


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How They Work

FDM

Plastic filament is fed into a heated nozzle.

The nozzle deposits molten plastic in thin layers.

Each layer cools and solidifies.

Common materials:

PLA

ABS

PETG

Nylon

Polycarbonate


SLA

A vat contains liquid resin.

A UV laser selectively hardens resin.

The part emerges layer by layer.

Common materials:

Standard resin

Tough resin

High-temperature resin

Flexible resin

Castable resin

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Surface Finish

FDM

Layer lines are visible.

May require sanding and painting for a presentation model.

SLA

Smooth, almost injection-molded appearance.

Excellent for customer presentations and aesthetic evaluation.

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Mechanical Properties

FDM Advantages

For functional engineering prototypes:

Better impact resistance.

Better toughness.

Better long-term durability.

Materials like Nylon and ABS can withstand practical use.


SLA Limitations

Many standard resins:

Are relatively brittle.

Can crack under impact.

May degrade with prolonged UV exposure.

Special engineering resins improve this but increase cost.

Cost Comparison

Prototype Service Bureau Pricing (Typical India)

Small component (~100 × 50 × 30 mm)

Technology

_____________________

Approximate Cost

Entry-level FDM

₹15,000 – ₹50,000

Professional FDM

₹1 lakh+


Entry-level SLA

₹25,000 – ₹80,000

Industrial SLA

Several lakhs to crores


Rule of Thumb

Need a cheap, strong, functional prototype? → FDM


Need a highly accurate, smooth, presentation-quality prototype? → SLA


Need both? → Often engineers first print in FDM for design verification, then make a final SLA prototype before tooling.

For automotive plastic parts, FDM prototypes are often 2–5 times cheaper, while SLA prototypes can provide 2–4 times better dimensional accuracy and surface finish.


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