What is a drawback of using thermoplastics in FDM?

Using thermoplastics in Fused Deposition Modelling (FDM) can indeed present certain challenges, and one significant drawback is the risk of warpage. Warpage occurs when the material cools unevenly during the printing process. Thermoplastics expand when heated and contract upon cooling, and if the cooling is not uniform, it can lead to deformation of the printed parts. This is particularly critical for larger prints or those with significant geometrical complexity, where the differential cooling rates can exacerbate the problem.

One of the causes for warpage in thermoplastics is the inherent stress that builds up during the printing process. If the base layer cools quickly while the top layers are still being printed, it can lead to the lower layers shrinking while the upper layers are still swollen from the heat, causing the part to lift or warp.

This issue is less prevalent in some other materials and processes, which can lead to a smoother overall print with fewer dimensional discrepancies. Recognizing and mitigating the risk of warpage is crucial for achieving high-quality prints in FDM, particularly when using thermoplastics that are more prone to this issue.

While other options might also present challenges in specific circumstances, the high risk of warpage stands out as