Fortus FDM Maintenance Tips & Best Practices | Argyle Materials

Every time a spool runs out or a build takes longer than expected and delays another job, you probably wonder how you can maximize the efficiency and lifespan of your material without sacrificing build quality.

After more than 25 years in the 3D printing business, the team at Argyle Materials has developed several practical ways to help you get more value from every spool, foundation sheet, and machine component.

Here are six of our favorite tips for improving the efficiency and maintenance of your Stratasys Fortus FDM machine.

1. Use Foundation Sheet Leftovers for Additional Builds

One of the most time-efficient practices that is often underutilized is making use of the leftover space on a foundation sheet.

Instead of waiting for the next available foundation sheet, you can use unused areas of the current sheet to start another build. This allows you to complete multiple jobs using the same foundation sheet, saving both time and material costs.

When printing the calibration square, look for areas where unused space will remain. Once you've identified these areas, determine whether the next part will fit into the available space. You can then position the additional part using the Control Center or the machine controls.

A Key Rule for Foundation Sheet Usage

Never start a small build in the center of your build tray or foundation sheet.

Position smaller parts toward available areas around the existing build whenever possible. This helps preserve usable foundation space for additional parts and allows you to maximize each build.

2. Always Combine Like-for-Like Materials

When reusing a Fortus foundation sheet, always use the same type of material for the next build.

For example:

• ABS should be combined only with ABS.
• ASA should be combined with ASA.
• Nylon should be combined with Nylon.
• TPU should be combined with TPU.
• PC should be combined with PC.
• Ultem should be combined with Ultem.
• PC-ABS should be combined with PC-ABS.

Avoid combining different materials, even when they may appear compatible. For example, PC-ABS should not be combined with ABS because these materials run at different Fortus build chamber temperatures.

Leftover material from a previous build can warp or curl when exposed to a different chamber temperature. These remnants may interfere with the print head and potentially cause a build failure.

When combining multiple builds on one foundation sheet, always make sure the next build uses the same material as the previous build.

This simple practice helps you maximize the use of your foundation sheet while reducing the risk of material-related build problems.

3. Dry Your Fortus FDM Material Properly

Moisture can negatively affect FDM materials and may contribute to poor print quality, material degradation, and build failures. Proper drying is particularly important for partially used spools or canisters that have been exposed to the environment.

The appropriate drying temperature depends on the material.

Recommended Drying Temperatures

Material	Approximate Drying Temperature	Recommended Time
ABS	65°C	8+ hours
PC-ABS	65°C	8+ hours
ASA	65°C	8+ hours
Nylon	45–55°C	24+ hours
Ultem	65–75°C	8+ hours

For new spools or canisters, Argyle Materials recommends drying the material for at least four hours with the canister lid off before loading it into the Fortus Model or Support material bays.

How to Dry a Partially Used Spool

When drying a partially used spool, place it vertically. This orientation increases the exposed surface area and helps prevent the filament wrap from falling down or crossing over the feed path.

Taping the filament vertically can also help prevent the material from spilling or becoming tangled.

For materials such as ABS, PC-ABS, and ASA, drying at approximately 65°C for eight hours or longer is generally recommended.

Nylon requires a lower temperature, around 45–55°C, but should be dried for a much longer period—typically 24 hours or more.

Ultem requires approximately 65–75°C. Do not exceed the recommended temperature, as excessive heat can cause the spool itself to warp.

Vacuum Ovens for Drying

Commercial vacuum ovens can provide better temperature control while the vacuum environment accelerates the drying process and helps remove moisture from the material.

One example is the DZF-6050 vacuum drying oven.

4. Store Fortus Material Canisters Properly

Proper storage is essential for protecting both partially used and brand-new Fortus material.

Partially used spools or canisters should be stored upright in a low-moisture, stable room-temperature environment.

For additional protection, consider using:

• Sealed storage bins
• Silica gel or other desiccants
• Nitrogen storage cabinets

What About New Material?

Brand-new FDM canisters and refill spools should also be stored in a low-moisture environment.

OEM and Argyle Materials products are typically supplied in sealed, moisture-resistant bags with desiccant, protecting until the material is opened.

Once a spool or canister has been opened, however, maintaining a stable storage environment becomes particularly important.

What Temperature Should You Use for Storage?

Room temperature is generally the best environment for storing FDM material.

Avoid extremely cold or hot environments.

Material stored in a cold environment may require additional time to reach the appropriate operating temperature before use. Rapid temperature changes can also contribute to condensation, which may introduce moisture into the material.

Excessive heat can cause similar problems, including spool deformation and increased moisture exposure.

The ideal storage environment is therefore:

• Stable room temperature
• Low humidity
• Minimal temperature fluctuations
• Protection from direct heat and moisture

5. Monitor and Replace Your Fortus Print Tips

Tip maintenance is critical for maintaining consistent build quality and avoiding expensive build failures.

The Fortus machine's odometer measures the amount of filament printed through the installed tip, in inches. This measurement helps determine when a tip is approaching the end of its useful life.

As a general guideline, avoid running a tip beyond approximately 1,000 inches.

For example, if the current tip is at 950 inches and your next build is expected to use another 100 inches, it is better to install a new tip before starting the build.

Replacing the tip in advance can help prevent a potential tip failure from causing an expensive build failure.

Clean the Tip Between Builds

Between builds, clean the exterior of the tip and remove debris from the white ceramic heat shield.

Polishing the heat shield with 600–1000 grit sandpaper can also help prevent material remnants from sticking to the surface and subsequently becoming embedded in a model layer.

Regular cleaning allows you to:

• Extend tip life
• Remove material buildup
• Inspect the tip for damage
• Monitor the tip's odometer
• Reduce the risk of material contamination

Store Tips Correctly

If you're switching from one material to another—for example, from ABS to PC—clean the tip before storing it.

Place the cleaned tip back into its delivery tube and store it at a stable temperature.

Proper storage helps protect the tip and makes it easier to reuse when needed.

6. Maintain Your Tips, Brushes, and Flickers

Regular maintenance can help extend the life of your Fortus components and reduce the risk of failed builds.

Argyle Materials' Purge Filament can be used to help extend tip life and decarbonize the melt chamber.

Regularly replacing the machine's brushes and flickers is also important. Worn brushes and flickers may not effectively remove purge remnants, allowing material debris to remain on the machine or potentially end up on your 3D-printed part.

Replacing these components regularly helps ensure purge remnants are properly scraped away and directed into the Fortus waste bin.

Get More From Your Stratasys Fortus FDM Machine

Efficient FDM production isn't just about running builds—it is also about properly managing your foundation sheets, materials, print tips, and machine components.

By following these six practices, you can:

• Maximize foundation sheet usage
• Reduce material waste
• Protect your filament from moisture
• Extend material shelf life
• Increase print-tip lifespan
• Reduce the risk of build failures
• Maintain consistent build quality
• Improve overall machine efficiency

With proper material storage, drying, foundation sheet planning, and routine tip maintenance, you can get more efficient and reliable performance from your Stratasys Fortus FDM machine.