Affiliation:
1. Mechanical Engineering Department, College of Engineering, Imam Mohammad Ibn Saud Islamic University (IMSIU), Riyadh 11432, Saudi Arabia
Abstract
Achieving precise dimensional accuracy and improving surface quality are the primary research and development objectives in the engineering and industrial applications of 3D printing (3DP) technologies. This experimental study investigates the pivotal role of solid model geometry tuning in enhancing the dimensional accuracy of affordable 3D printing technologies, with a specific focus on economical engineering applications. This experiment utilises low-cost Material Extrusion/Fused Filament Fabrication (FFF) and Stereolithography (SLA)/Digital Light Processing (DLP) 3D-printed patterns for the meticulous measurement of errors in the X, Y, and Z directions. These errors are then used to refine subsequent solid models, resulting in a marked improvement in dimensional accuracy (i.e., 0.15%, 0.33%, and 2.16% in the X, Y, and Z directions, respectively) in the final DLP 3D-printed parts. The study also derives and experimentally validates a novel and simple mathematical model for tuning the solid model based on the calculated linear directional errors (ei, ej, and ek). The developed mathematical model offers a versatile approach for achieving superior dimensional accuracy in other 3D printing processes. Medium-sized (4 to 10 cm) wax-made DLP- and PLA-made patterns are used to test the ceramic mould-building capacity for rapid casting (RC), where the FFF-based 3D-printed (hollow inside) pattern favours successful RC. This work comprehensively addresses the critical challenges encountered in low-cost DLP and FFF processes and their scopes in engineering applications. It provides novel suggestions and answers to improve the effectiveness, quality, and accuracy of the FFF 3D printing process for future applications in RC.
Funder
Deanship of Scientific Research, Imam Mohammad Ibn Saud Islamic University
Subject
Electrical and Electronic Engineering,Industrial and Manufacturing Engineering,Control and Optimization,Mechanical Engineering,Computer Science (miscellaneous),Control and Systems Engineering