Dimensional Tolerances for Additive Manufacturing: Experimental Investigation for Fused Deposition Modeling

Lieneke, Tobias; Denzer, Vera; Adam, Guido; Zimmer, Detmar

doi:10.1016/j.procir.2016.02.361

Cited by 98 publications

(52 citation statements)

References 16 publications

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“…Results for each sample and averages are shown in Table V. As expected, surface roughness values, particularly R a which is the most common comparative value (Todhunter et al, 2017), are greater than studies conducted using other FFF hardware that has typically focused on more accurate processes with layer heights <0.254 mm (Kim and Oh, 2008;Lieneke et al, 2016). While the data collected in this study requires validation through more specific surface roughness testing, it can be used as an initial benchmark for future studies on the BigRep ONE and other large area AM equipment which is currently lacking within academia.…”

Section: Metrologymentioning

confidence: 64%

A design for additive manufacturing case study: fingerprint stool on a BigRep ONE

Novak

O’Neill

2019

RPJ

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Purpose This paper aims to present new qualitative and quantitative data about the recently released “BigRep ONE” 3 D printer led by the design of a one-off customized stool. Design/methodology/approach A design for additive manufacturing (DfAM) framework was adopted, with simulation data iteratively informing the final design. Findings Process parameters can vary manufacturing costs of a stool by over AU$1,000 and vary print time by over 100 h. Following simulation, designers can use the knowledge to inform iteration, with a second variation of the design being approximately 50 per cent cheaper and approximately 50 per cent faster to manufacture. Metrology data reveal a tolerance = 0.342 per cent in overall dimensions, and surface roughness data are presented for a 0.5 mm layer height. Research limitations/implications Led by design, this study did not seek to explore the full gamut of settings available in slicing software, focusing predominantly on nozzle diameter, layer height and number of walls alongside the recommended settings from BigRep. The study reveals numerous areas for future research, including more technical studies. Practical implications When knowledge and techniques from desktop 3 D printing are scaled up to dimensions measuring in meters, new opportunities and challenges are presented for design engineers. Print times and material costs in particular are scaled up significantly, and this study provides numerous considerations for research centers, 3 D printing bureaus and manufacturers considering large-scale fused filament fabrication manufacturing. Originality/value This is the first peer-reviewed study involving the BigRep ONE, and new knowledge is presented about the practical application of the printer through a design-led project. Important relationships between material volume/cost and print time are valuable for early adopters.

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Section: Metrologymentioning

confidence: 64%

A design for additive manufacturing case study: fingerprint stool on a BigRep ONE

Novak

O’Neill

2019

RPJ

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“…While all of these are important to examine, the most important from the perspective of engineering design are the dimensional accuracy and repeatability of the final parts. It has been observed that most of the problems with the dimensional accuracy in AM are due to the material behavior [13,[21][22][23] and to the limitations and mechanics of the processing equipment [24][25][26]. Since most AM processes involve heating the material past the glass transition temperature, shrinkage of the material is a concern; this shrinkage can both destroy the dimensional integrity of the part and introduce residual stresses, potentially reducing the material fatigue life as well.…”

Section: Of 27mentioning

confidence: 99%

Full-Density Fused Deposition Modeling Dimensional Error as a Function of Raster Angle and Build Orientation: Large Dataset for Eleven Materials

Messimer¹,

Pereira²,

Patterson³

et al. 2018

Preprint

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This report describes the collection of a large dataset (6930 measurement) on dimensional error in the fused deposition modeling (FDM) additive manufacturing process for full-density parts. Three different print orientations were studied, as well as seven raster angles (0 • , 15 • , 30 • , 45 • , 60 • , 75 • , and 90 • ) for the rectilinear infill pattern. All measurements were replicated ten times on ten different samples to ensure a comprehensive dataset. Eleven polymer materials were considered: acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), high-temperature PLA, wood-composite PLA, carbon-fiber-composite PLA, copper-composite PLA, aluminum-composite PLA, high-impact polystyrene (HIPS), polyethylene terephthalate glycol-enhanced (PETG), polycarbonate, and synthetic polyamide (nylon). The samples were ASTM-standard impact testing samples, since this geometry allows the measurement of error on three different scales; the nominal dimensions were 3.25mm thick, 63.5mm long, and 12.7mm wide. This dataset is intended to give engineers and product designers a benchmark for judging the accuracy and repeatability of the FDM process for use in manufacturing of end-user products. Dataset: Attached with manuscriptDataset License: CC-BY

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“…The geometrical versatility of the parts produced by SLS represents the top characteristic of this technology . The deflections from the nominal shape and size and also the mechanical properties of the obtained parts are representing a challenging aspect …”

Section: Introductionmentioning

confidence: 99%

“…1,2 The deflections from the nominal shape and size and also the mechanical properties of the obtained parts are representing a challenging aspect. 3,4 The mechanical characterization of SLS plastic parts was conducted through tensile tests by some authors, 5,6 while in other studies, flexural properties were determined according to manufacturing parameters, 7,8 leading to the conclusion that process parameters are greatly influencing the mechanical properties of samples.…”

Section: Introductionmentioning

confidence: 99%

Flexural properties of selectively sintered polyamide and Alumide

Marșavina

Stoia

2019

Mat Design & Process Comms

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Selective laser sintering is one of the most versatile additive manufacturing technologies that make possible fabrication of good resolution parts that possesses adequate mechanical properties. The variables involved in the process are strongly influencing the geometrical and mechanical properties of the parts. This paper focuses on determining the flexural properties of two materials: polyamide PA2200 and Alumide. The fabrication process was conducted on EOS Formiga P100 machine by modifying the orientation of the samples in the XY building plane. In the same time, the rest of the controllable variables (laser power, scan velocity, layer thickness, temperatures, and beam offset) remain unchanged for the entire process. This finding can be used in design of additive manufacturing parts.

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Dimensional Tolerances for Additive Manufacturing: Experimental Investigation for Fused Deposition Modeling

Cited by 98 publications

References 16 publications

A design for additive manufacturing case study: fingerprint stool on a BigRep ONE

A design for additive manufacturing case study: fingerprint stool on a BigRep ONE

Full-Density Fused Deposition Modeling Dimensional Error as a Function of Raster Angle and Build Orientation: Large Dataset for Eleven Materials

Flexural properties of selectively sintered polyamide and Alumide

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