Fused Deposition Modeling (FDM) uses a heated filament, like ABS or PLA, which is extruded through a nozzle that follows a programmed path to deposit material layer by layer on a build platform. The thermoplastics used in FDM create strong, durable parts that can endure mechanical stress. Its use of standard materials makes it a cost-effective choice for prototyping and low-volume production.

Advantages:

• High Strength and Durability: Polycarbonate (PC) is one of the strongest thermoplastics available for FDM 3D printing, making it ideal for parts that need to withstand heavy mechanical stress and high-impact forces.
• Heat Resistance: PC has excellent thermal stability, allowing it to maintain its properties at high temperatures, making it suitable for parts exposed to heat or requiring high temperature performance.
• Dimensional Accuracy: PC offers high precision, ensuring parts have accurate dimensions and tight tolerances, which is essential for functional prototypes and manufacturing tools.
• Toughness: PC combines strength with flexibility, meaning parts can absorb shocks and impacts without breaking, making it suitable for industrial, automotive, and mechanical applications.
• Chemical Resistance: It exhibits good resistance to various chemicals, including oils and greases, enhancing its performance in demanding environments.
• Transparency: Although not available in all forms, PC is naturally transparent, making it useful in applications requiring clear parts.

Disadvantages:

• Printability Challenges: PC can be difficult to print with due to its tendency to warp and shrink. A heated build chamber and controlled environment are often required for optimal results.
• Moisture Sensitivity: Like other hygroscopic materials, PC absorbs moisture from the air, which can affect print quality if not stored properly in dry conditions.
• Higher Cost: PC is more expensive than general-purpose materials like PLA and ABS, which may increase production costs, particularly for large or high-volume prints.
• Post-Processing Needs: PC prints often require additional post-processing, such as surface smoothing or annealing, to achieve the desired finish and strength.
• Limited Color Options: PC for FDM printing is typically available in a limited range of colors, such as white, restricting design flexibility.
• Brittleness in Thin Sections: Although PC is generally tough, it can be brittle when printed in thin layers, limiting its use for parts requiring fine details.