Dimensional precision and robustness of Fused Deposition Modelling (FDM) additive manufacturing processes

增材制造（AM）为设计师提供了一系列独特的新可能性，以设计具有新形状的新组件。熔融沉积成型已成为最普遍的增材制造工艺之一，由于这些机器的成本相对较低。然而，FDM对设计人员的实用性受到这些机器的性能能力的限制，特别是对于复杂或小型结构。因此，大部分的使用是由“业余爱好者”和许多零件需要几个迭代的生产，由于制造的不准确性。虽然大多数机器宣传册都将“分辨率”和轴速作为性能指标，但尺寸精度往往没有注明。该项目旨在探索3D打印技术的尺寸能力，特别是FDM机器的尺寸能力。第一个产出将是对不同机器当前能力的更深入了解，如果这些技术要被设计师使用，这是必不可少的数据。这些数据将用于提供第二个输出，即使用稳健机床设计原则重新设计FDM机床。实验将在尽可能广泛的FDM机器上进行。这将包括机器可重复性的基线研究以及整个构建体积的尺寸精度表征。这些实验还将确定不同工艺设置对打印质量的相互依赖性和影响。预计对实验阶段与所采用的基本机器设计原则相关的输出的分析将确定机器设计如何影响所观察到的变化。这一阶段的成果将用于设计一台新的FDM机床，目标是生产具有高水平尺寸精度和可重复性的零件。该项目涵盖了EPSRC工程设计和制造技术的研究领域。

Additive Manufacturing (AM) presents designers with a unique set of new possibilities, to design new components with new shapes. Fused Deposition Modelling has become one of the most ubiquitous of AM processes, due to the comparatively low cost of these machines. However, the utility of FDM to designers is limited by the performance capabilities of these machines, especially with complex or small structures. As a result, much of the use is by 'hobbyists' and many parts require several iterations of production due to inaccuracies in manufacture. Whilst most machine brochures cite 'resolution' and axis speed as an indicator of performance, dimensional precision is extremely often not indicated.This project aims to explore the dimensional capability of 3D printing technologies, more specifically that of FDM machines. The first output will be a greater understanding of the current capability of different machines, which is essential data if these technologies are to be used be designers. This data will be used to deliver the second output, the re-design of an FDM machine using the principles of robust machine tool design. Experiments will be conducted on as wide a set of FDM machines as is possible. This will include a baseline study of machine repeatability as well as the characterisation of dimensional accuracy over the full build volume. These experiments will also establish the interdependencies and impact of different process settings on print quality.It is expected that analysis of the outputs from the experimental phase in relation to the underlying machine design principles adopted, will determine how the machine design might influence the variations seen. Outputs from this phase will be used to design a new FDM machine, with the objective of producing parts with a high level of dimensional accuracy and repeatability.The project covers the EPSRC research areas of Engineering Design and Manufacturing Technologies.