Geometrical and Dimensional Deviations of Fused Deposition Modelling (FDM) Additive-Manufactured Parts

This research investigates the influence of printing parameters and different materials on the geometrical and dimensional deviations of Fused Deposition Modelling (FDM) additive manufacturing. Using the Taguchi method, experiments with four factors are designed: print layer height, printing material, printing speed, and nozzle size, employing an L9 orthogonal array. Deviations in flatness, perpendicularity, parallelism, cylindricity, spherical form, and surface roughness of 3D-printed parts are evaluated. The results reveal that print speed and nozzle size significantly affect flatness and surface roughness, while layer height and material influence perpendicularity and parallelism deviations. Notably, nozzle size critically impacts cylindricity and spherical form deviations. Our study demonstrates that lower printing speed, smaller nozzle diameter, and reduced layer height are not universally optimal; instead, parameter adjustments based on specific geometrical requirements and part orientation are necessary. These findings are essential for improving the accuracy and quality of FDM-printed parts, supporting their broader application in precision manufacturing industries.