Assessment of Dimensional Fidelity in <scp>3D</scp> Printed <scp>PLA</scp> Casting Patterns via Laser Scanning

ABSTRACT Dimensional accuracy in 3D‐printed PLA patterns is critical in casting applications to ensure conformity between the printed model and the final cast component. This study investigates the influence of key fused deposition modeling (FDM) process parameters—layer height, printing temperature, printing speed, and scale factor—on the dimensional fidelity of PLA parts and also identifies the most influential parameters. A total of 27 samples were fabricated using a factorial combination of parameters, and high‐resolution laser scanning was employed to evaluate dimensional deviations against the nominal CAD model using mean deviation and standard deviation metrics. Statistical analysis through Analysis of Variance (ANOVA) identified printing temperature as the most significant factor affecting dimensional accuracy, while layer height and printing speed exhibited comparatively smaller effects within the tested range. The optimal parameter set 0.24 mm layer height, 200°C printing temperature, 60 mm/s printing speed, and 1.00% scale yielded minimal dimensional deviation and excellent repeatability. Validation tests confirmed the robustness of this configuration, demonstrating improved accuracy and reduced variability. The findings serve as a valuable reference for optimizing FDM print conditions, offering practical insights for enhancing dimensional precision in both prototype development and functional part manufacturing.