Workflow example: FDM printing

Overview

This example demonstrates how to implement a simple FDM 3D printing workflow using workstations in Phasio. The workflow covers the entire production process from initial part queuing through final post-processing and quality control, providing a practical reference for manufacturers setting up FDM production workflows.

FDM 3D printing workflow structure

This implementation creates a six-step workflow that efficiently manages FDM printing operations while maintaining clear visibility and control over each production stage, accommodating the unique requirements of filament-based printing.

Workflow sequence

The example workflow consists of six sequential workstations:

1. Waiting for Slicing: Initial backlog management.
2. Printing: Active production with print preparation.
3. Post-Printing: Essential post-production processes (part removal, support removal, etc.)
4. Polishing: Optional surface finishing operations.
5. Quality Control: Final inspection and validation.
6. Completed: Workflow completion and order fulfilment.

Workstation configuration

Workstation details

Waiting for Slicing

Manages the backlog of parts that have been scheduled for production.

• Uses the Basic workstation type, which has no operational effect.
• Parts are only moved out of this station—no processing occurs here.

Printing

When parts move into this workstation, the Upload 3MF step type allows manufacturers to download parts grouped by material and color constraints.

• Manufacturers can download either:
  • a .camspec file for slicer software integration, or
  • a .zip file containing parts for local slicing preparation.
• After preparing the sliced print job, parts can be progressed either individually, or as a group, by uploading the corresponding .3mf or .gcode file exported from the slicer software.
• In most cases, parts move individually, as prints typically consist of a single part—unless a full build plate is prepared.

Post-Printing

Supports post-processing steps immediately after printing.

• Parts are grouped by material and color constraints for efficient batch handling.
• Uses the Inherit from Previous Step naming strategy to preserve custom job names assigned during the Printing stage.
• Maintains clear job identification through key post-printing processes like part removal from the build plate and support structure removal.

Polishing

An optional finishing workstation where parts are grouped by both material and color constraints, ensuring identical finishing treatments are processed together. Using the Inherit from Previous Step naming strategy maintains job identification as parts undergo surface finishing operations to improve print quality and appearance.

Quality Control

Parts moving into this workstation have no grouping constraints. The Inherit from Previous Step naming strategy maintains traceability by preserving job names from earlier stages during final inspection and validation.

Completed

The final stage of the workflow.

• Parts arriving here are automatically renamed with a “Finished” prefix using the Always Rename naming strategy.
• This workstation is designated as the final station (where Final Station = True), marking the completion of the production workflow.
• As parts reach this stage, the order’s completion rate progresses toward 100%. Once all parts in an order are finished, they are automatically removed from the Completed workstation.
• This station can be used to indicate storage until the entire order is prepared for shipment.

Workflow operation

Part progression and filtering

When advancing parts from one workstation to the next, manufacturers can apply filters to optimize build preparation and workflow efficiency. Filters include maximum volume, customer orders, due dates, and destination workstations. This functionality is especially useful for grouping parts that share identical material and colour requirements, or post-processing workflows.

Scrap management

At any workstation, individual parts can be marked as scrapped due to quality issues or production errors. Manufacturers can optionally provide a scrap reason for quality tracking and schedule replacement quantities to ensure order fulfilment timelines are maintained.

Part progression flow

1. Parts automatically enter the workflow at Waiting for Slicing when an order is placed.
2. Production teams download parts grouped by material and color from the Printing workstation.
3. Print preparation occurs offline with slicer software.
4. G-code upload progresses the prepared print job to Printing.
5. Manufacturers manually moves parts through the remaining post-printing and finishing stages.
6. Automatic workflow assignment allows parts to bypass the Polishing workstation if surface finishing is not required.

Workflow efficiency benefits

This example illustrates how workstation configuration can be adapted for FDM-specific requirements while accommodating the unique characteristics of filament-based printing processes. Some advantages include:

• Material and color-based grouping minimizes filament changes and reduces setup time.
• Flexible batch processing supports both single-part and multi-part print jobs via .3mf and G-code uploads.
• Individual part tracking provides precise visibility, well-suited to FDM’s typically smaller batch sizes.
• Clear workflow visibility ensures proper handling of support removal, finishing steps, and downstream operations.