Fine Detail Resolution: The New Frontier of Micro-Precision
When standard industrial 3D printing reaches its physical limits, Fine Detail Resolution (FDR) takes over.
By utilizing a specialized CO laser with an ultra-fine beam diameter, Prototal delivers a technology capable of producing intricate, high-definition components that were previously only possible through high-end injection moulding. FDR is not just about being small; it is about achieving sharp-edged feature resolution and functional complexity in PA 1101 at a scale that redefines what is possible in additive manufacturing.
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High-Resolution Performance for Complex Systems
FDR technology bridges the gap between the speed of additive manufacturing and the intricate detail of micro-moulding. By focusing energy into a beam significantly smaller than standard SLS lasers, we can produce wall thicknesses and internal geometries that maintain mechanical integrity at a microscopic level.
Industries benefiting from FDR:
- Electronics: Micro-connectors and intricate sensor housings
- Medical Technology: Micro-fluidic components and surgical tools
- Aerospace & Defence: Lightweight, miniature actuators and sensors
- Automotive: High-precision connectors for e-mobility and autonomous systems
The Power of PA 1101
Unlike standard polymers, FDR process utilises PA 1101, a bio-based polyamide. This material offers the high impact resistance and elongation at break required for functional living hinges and snap-fits, ensuring that even your smallest components are rugged enough for end-use industrial applications.
Miniaturisation at Scale
As industries push for smaller, lighter, and more integrated devices, FDR provides the tool-less path to miniaturisation. We enable engineers to iterate rapidly on micro-scale designs and move directly into serial production without the multi-month lead times of micro-tooling.
Surface Engineering & Durability
While FDR ensures precision, Vapor Smoothing provides the finish needed for true functionality. By sealing PA 1101 without losing sharp details, it eliminates porosity and achieves an IP-rated, non-porous surface. This creates a professional, injection-moulded look while significantly increasing the fatigue life and durability of your micro-components.
Advanced Production Facility
Our FDR technology is centralized at our facility in Dornbirn, ensuring specialized process control. For medical applications requiring the highest regulatory standards, we offer production under ISO 13485 certification. This combines micron-level precision with the rigorous documentation and traceability essential for the global healthcare sector.
PA 1101
Engineered for micro-scale functional integrity, PA 1101 is a bio-based polyamide that offers exceptional impact resistance and the high elongation required for complex, moving assemblies.
- Exceptional Mechanical Toughness
- Superior Fine-Detail Definition
- Durable Chemical Resistance
Datasheet at a Glance
| Fine Detail Resolution | Density (g/cm³) | Tensile strength (MPa) | Tensile modulus (MPa) | Elongation at break | Charpy IS (kJ/m² @ 23°C) | HDT (°C @ ~1.8 MPa) |
|---|---|---|---|---|---|---|
| PA 1101 | 1.03 | XY 50 / Z 48 | XYZ 1650 | XY 30% | XY N / Z 85 (unnotched) | 47 |
The data shown is indicative and intended for reference only. Material properties may vary depending on printing conditions and technology. Although care has been taken to ensure accuracy, typographical or data entry errors may occur. For authoritative specifications, please refer to the original manufacturer datasheets provided under each material.
3D Printing Guidelines
Our helpful guides are specifically designed to assist you before submitting your design to us. We always strive to achieve the best possible outcome, and by following our guidelines, you can be confident that your design will be of the highest quality.
Get in touch with us if you need guidance, we are happy to help you!
How FDR Achieve Micron-Level Accuracy
The FDR process is a specialised evolution of Selective Laser Sintering (SLS), optimized for extreme detail:
The Step-by-step Process in FDR
- Digital Pre-Processing: Your CAD data is sliced at ultra-thin layer heights to capture every nuance of the geometry.
- Ultra-Fine Laser Sintering: A specialized CO laser, featuring a beam diameter significantly smaller than industrial standards, scans the powder bed of PA 1101.
- High-Resolution Fusion: Because the energy is so concentrated, the heat-affected zone is minimised, allowing for sharper corners, thinner walls (down to 0.22 mm), and intricate internal channels.
- Precision Cooling: Controlled thermal management ensures that the micro-features remain dimensionally stable and free from warping during the solidification phase.
Bring Your Design to Life
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Quote Your Next Project
Looking for high-quality industrial 3D printing solutions tailored to your needs? Our team is ready to provide a detailed quote for your project. Simply share your specifications, and we’ll deliver a clear, competitive estimate — no surprises, just precision and reliability.
Why choose us?
- 3D printing solutions for any scale and complexity
- Fast and accurate quoting process
- Local presence close to your business and business needs
FAQs
Do you have questions regarding FDR Industrial 3D Printing? Find the most common questions and answers about the subject here.
Our biggest industrial FDR platform from EOS can accommodate build volumes up to 200 x 250 x 125 mm depending on part geometry.
The primary difference lies in the laser beam diameter. While standard SLS uses a broader beam for general industrial parts, FDR utilizes a specialised CO laser with an ultra-fine focal point. This allows for significantly higher resolution, enabling the production of sharp edges and wall thicknesses as thin as 0.22 mm, which is beyond the capability of standard powder-bed systems.
Vapour Smoothing is a controlled process that seals the surface of the PA 1101 without removing material or rounding off critical technical edges. It improves the surface finish and airtightness of the part while maintaining the high dimensional accuracy achieved during the FDR printing process.
Unlike many high-resolution resins, from technologies such as SLA, that can be brittle, PA 1101 is a bio-based polyamide that offers exceptional impact resistance and elongation at break. This makes it the ideal material for functional micro-components like living hinges and snap-fits that must withstand mechanical stress without failing.
We offer a range of post-processing services to ensure your 3D printed parts meet the highest standards of quality, precision, and aesthetics.
Manufacturing should not be transactional. At Prototal we value a partnership, which is why you will get a dedicated contact person close to your operations that knows your business and business needs. To start our future partnership, please reach out to the local team within your area that can be found under Contact us or send us an e-mail:
- Norway: post@prototal.no or +47 74 09 06 00
- Sweden: am@prototal.se or +46 (0) 36-38 72 00
- Denmark: 3dp@prototal.dk or +45 43 99 37 36
- United Kingdom: info@prototaluk.com or +44 01635 635855
- Italy: info@prosilas.com or +39 0733 892665
- Austria, Germany & Switzerland: 3dp@prototal.at or +43 5572 52946-9
As a flexible partner we can offer lead times down to 1 working day depending on the selection of post-processing and quality control. Usually, you can expect a lead time within the range of 2-3 working days, depending on same variables as stated above.*
*While Prototal offers industry-leading turnaround times, all delivery schedules are estimates based on standard operating conditions. Final lead times are subject to local availability, part geometry, build volume, and specific material selection. Complex geometries requiring extensive support structures or high-performance materials may require additional processing time to ensure structural integrity and dimensional accuracy.
