Fused Deposition Modeling (FDM) is a relatively new prototyping technique in which parts can be produced rapidly and accurately.The present work started with the identification of the bench mark. Prototypes were built with ABS plastic material and measurements were made on the co-ordinate measuring machine from which IT grades were calculated to check the dimensional accuracy of the components. The purpose of this study is to find whether the FDM process is capable of producing a pattern for manufacturing a die for hand tool with good dimensional accuracy. The study involves best settings of machine by varying the part orientations and studying the effect on the consumption of the model material, support material and the time taken for production. Morphology of the components at various orientations was also studied to give an insight to the quality of the product produced at various orientations. Measured mechanical properties like micro hardness indicated the suitability of the process. Final components produced are acceptable as per ISO standard UNI EN 20286-I (1995) and DIN16901.