An Optimization Method for Improving the Accuracy of Multiple Parametric Printed Parts in FDM

Abstract

Dimensional accuracy is one of the main key features for achieving the desired fit in fused deposition modeling (FDM). Printer tolerance and build orientation are the main challenges faced during the prototyping phase and hence there is a need for a method to calibrate the printer and the material being used that can serve as a guide to designing the clearances of mating parts. This paper presents the design and validation of a tolerance prototype and the study, which, with some analysis and data representation, gives the optimal solution. Hence, this can be used to compensate for the variations in dimensions while printing. A tolerance prototype model consisting of squares and circles of various dimensions is developed in Siemens NX 11.0 that tests the printer in three different orientations i.e., x-axis, y-axis and z-axis. FDM printers Accucraft i250 (heat bed type) and Flashforge (non-heat bed type) are used to print the prototype. The dimensions are measured with calipers to arrive at the dimensional correction templates that are further used to design and validate movable components.