Understanding error generation in fused deposition modeling

Bochmann, Lennart; Bayley, Cindy; Helu, Moneer; Transchel, Robert; Wegener, Konrad; Dornfeld, David

doi:10.1088/2051-672x/3/1/014002

Cited by 57 publications

(34 citation statements)

References 17 publications

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“…Most of the issues and downsides reported by the students about machine failures or FDM process accuracy are well documented in the literature (Armillotta, 2006, Bakar et al, 2010, Bochmann et al, 2015, Boschetto and Bottini, 2014, Dimitrov et al, 2006, Johnson et al, 2014, Mahesh et al, 2004, Pei et al, 2011. As concerns the fourth question about Changes, in order to solve the abovementioned problems related to the wrong clearances, students would modify the product geometry in terms of tolerances assigned to joints and integrated movable parts.…”

Section: "Difficulties In Designing a Component To Be Manufactured Bymentioning

confidence: 99%

Impact of additive manufacturing on engineering education – evidence from Italy

Minetola

Iuliano

Bassoli

et al. 2015

Rapid Prototyping Journal

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Purpose - The purpose of this paper is to evaluate how the direct access to additive manufacturing (AM) systems impacts on education of future mechanical engineers, within a Master's program at a top Italian University. Design/methodology/approach - A survey is specifically designed to assess the relevance of entry-level AM within the learning environment, as a tool for project development. The survey is distributed anonymously to three consecutive cohorts of students who attended the course of "computer-aided production (CAP)", within the Master of Science Degree in Mechanical Engineering at Politecnico di Torino. The course includes a practical project, consisting in the design of a polymeric product with multiple components and ending with the production of an assembled prototype. The working assembly is fabricated by the students themselves, who operate a fused deposition modelling (FDM) machine, finish the parts and evaluate assemblability and functionality. The post-course survey covers diverse aspects of the learning process, such as: motivation, knowledge acquisition, new abilities and team-working skills. Responses are analyzed to evaluate students' perception of the usefulness of additive technologies in learning product design and development. Among the projects, one representative case study is selected and discussed. Findings - Results of the research affirm a positive relationship of access to AM devices to perceived interest, motivation and ease of learning of mechanical engineering. Entry-level additive technologies offer a hands-on experience within academia, fostering the acquisition of technical knowledge. Research limitations/implications - The survey is distributed to more than 200 students to cover the full population of the CAP course over three academic years. The year the students participated in the CAP course is not tracked because the instructor was the same and there were no administrative differences. For this reason, the survey administration might be a limitation of the current study. In addition to this, no gender distinction is made because historically, the percentage of female students in Mechanical Engineering courses is about 10 per cent or lower. Although the answers to the survey are anonymous, only 37 per cent of the students gave a feedback. Thus, on the one hand, impact assessment is limited to a sample of about one-third of the complete population, but, on the other hand, the anonymity ensures randomization in the sample selection. Practical implications - Early exposure of forthcoming designers to AM tools can turn into a "think-additive" approach to product design, that is a groundbreaking conception of geometries and product functionalities, leading to the full exploitation of the possibilities offered by additive technologies. Social implications - Shared knowledge can act as a springboard for mass adoption of AM processes. Originality/value - The advantages of adopting AM technologies at different levels of education, for diverse educational purposes and discipline...

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Section: "Difficulties In Designing a Component To Be Manufactured Bymentioning

confidence: 99%

Impact of additive manufacturing on engineering education – evidence from Italy

Minetola

Iuliano

Bassoli

et al. 2015

Rapid Prototyping Journal

View full text Add to dashboard Cite

show abstract

“…While all are important considerations, the most essential from the perspective of engineering design are the dimensional accuracy and repeatability of the final parts. It was observed that most of the problems with the dimensional accuracy in AM are due to the material behavior [16,[24][25][26] and to the limitations and mechanics of the processing equipment [27][28][29]. Since most AM processes involve heating the material past the melting temperature, shrinkage of the material is a concern as it cools in layers; this shrinkage can both destroy the dimensional integrity of the part and introduce residual stresses, potentially reducing the material fatigue life as well.…”

Section: Introductionmentioning

confidence: 99%

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

Messimer

Pereira

Patterson

et al. 2019

JMMP

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This paper describes the collection of a large dataset (6930 measurements) 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 . 25 mm thick, 63 . 5 mm long, and 12 . 7 mm wide. This dataset is intended to give engineers and product designers a basis for judging the accuracy and repeatability of the FDM process for use in manufacturing of end-user products.

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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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Understanding error generation in fused deposition modeling

Cited by 57 publications

References 17 publications

Impact of additive manufacturing on engineering education – evidence from Italy

Impact of additive manufacturing on engineering education – evidence from Italy

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

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

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