Improving surface quality and mechanical strength through the optimization and enhancement of Fused Deposition Modelling (FDM) for non-planar 3D printing

This study aims to enhance the Fused Deposition Modelling (FDM) printing process by utilizing a printing method that deviates from traditional planar techniques and incorporates three-dimensional (3D) layers, assessing the features and qualities of the 3-axis non-planar FDM printing process. To achieve this, the primary specifications of the printer used were analysed and fine-tuned. Planar samples were printed with angles varying from 10º to 30º and extrusion widths between 0.3 mm and 0.7 mm. Concentric and parabolic structures were produced using the planar printing method to examine how the parameters affect the quality of the printed samples. Based on the initial findings, the parameters were refined for printing widths between 0.4 mm and 0.6 mm, while variations were made in printing speed, extrusion multiplier, and overlap. Additionally, investigations were conducted on mechanical strength, increased printing angle (50º to 90º), and roughness assessments of both planar and non-planar surfaces. By constructing a test component to evaluate the practicality of non-planar printing, the findings indicated the potential to modify the 3D printer to produce non-planar forms, thereby improving strength by up to 11 % for non-planar XY mechanical samples and up to 24 % for non-planar Z samples, and featuring designs with diverse angles up to higher angles (90°). The roughness results indicated a 61.7 % improvement in surface quality for the non-planar printing technique and a 34 % improvement for the optimized non-planar printing technique compared to the planar technique. Furthermore, this technique proves to be environmentally friendly as it eliminates the need for support.