Comparison of dimensional accuracy between commercial and professional FDM 3D printers: a comprehensive analysis

This study focuses on the comparative analysis of dimensional accuracy between commercial and professional Fused Deposition Modeling (FDM) 3D printers. The commercial segment encompasses 3D printers such as the Creality CR 6-SE and Zortrax M200, categorized as consumer-grade FDM 3D printers within a price range of €350 to €1,800. Conversely, the professional segment includes the MakerBot Method X and Stratasys F370, high-performance systems priced from €6,000 up to €50,000 (Stratasys F370). As part of the experimental methodology, a standardized test sample was designed to incorporate a variety of geometric features, including spherical elements, chamfers, cylindrical shapes, cuboid structures or holes. This design was intended to evaluate the printers’ capabilities in producing diverse geometries with precision. For each of the four FDM 3D printers, five identical samples were fabricated to ensure statistical robustness and reduce the impact of random manufacturing variances. The fabricated samples were scanned using the GOM ATOS II Triple Scan, an advanced optical 3D scanning system equipped with a measurement volume of MV170. The scanned data were analyzed and compared to the original CAD model using GOM Inspect software, a specialized tool for dimensional analysis and inspection. The study’s analytical framework involved quantifying deviations between the printed samples and the CAD reference, with a focus on evaluating the impact of printer type, geometric complexity, and material properties on dimensional accuracy. The findings provide a comprehensive assessment of the trade-offs between dimensional accuracy and cost across the selected 3D printers. The results reveal critical insights into the performance of commercial versus professional FDM systems, highlighting their respective strengths and limitations. These conclusions aim to assist users in selecting the most suitable equipment for applications where dimensional precision and budget constraints are critical considerations.