Modeling machine motion and process parameter errors for improving dimensional accuracy of FDM machines

[+] Author and Article Information
Jiaqi Lyu

Department of Mechanical Engineering, Stevens Institute of Technology, Hoboken, NJ, 07030

Souran Manoochehri

Fellow of ASME, Department of Mechanical Engineering, Stevens Institute of Technology, Hoboken, NJ, 07030

1Corresponding author.

ASME doi:10.1115/1.4041328 History: Received April 18, 2018; Revised August 17, 2018


The dimensional accuracy of Fused Deposition Modelling (FDM) machines is dependent on processing parameters and machine types. In this study, extruder temperature, layer thickness and infill density are selected as variable and optimized for three FDM machines, namely, Flashforge Finder, Ultimaker 2 go and XYZ da Vinci 2.0 Duo. Experiments have been conducted using Taguchi method and the interactions between processing parameters are analyzed. An integrated error model combining processing parameters and machine motions is developed to improve the dimensional accuracy of fabricated parts. According to the dimensional deviations between fabricated parts and CAD model, a set of coefficients are calculated for each machine and the optimized parts are manufactured accordingly. Through comparing the dimensional deviations of parts manufactured before and after optimization, the effectiveness of the integrated error model is analyzed and validated for the three FDM machines.

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