Comparison of real-time geometric analyses to predict warping deformation in fused filament fabrication

Hannah D. Budinoff, Yilin Sun, Sara McMains

Research output: Chapter in Book/Report/Conference proceedingConference contribution

1 Scopus citations

Abstract

This work describes an experimental study to assess if analytical and empirical models can estimate the risk of warping deviation for parts made using fused filament fabrication based on part geometry. We also examine how the accuracy of the prediction varies for different machines and materials. If the predictive models can estimate risk of warping for a given part geometry, they can help enable better design for additive manufacturing so that designers can change part geometry early in the design process to have more easily-manufacturable parts, or choose an alternative orientation to optimize dimensional accuracy at the process planning stage. Specifically, we evaluate the extent to which two analytical models and one empirical model can assess the risk of warping for approximately rectangular parts with varying dimensions. We analyze dimensional accuracy data for parts with different length, height, and fillet type that were printed in ABS and PLA on different fused filament fabrication machines. After evaluating the three models, we found that the empirical model had the best performance over all datapoints. However, the analytical models showed promise but need further refinement on how the prediction of warping deviation depends on part height. Areas for additional research are highlighted.

Original languageEnglish (US)
Title of host publicationAdditive Manufacturing; Advanced Materials Manufacturing; Biomanufacturing; Life Cycle Engineering; Manufacturing Equipment and Automation
PublisherAmerican Society of Mechanical Engineers
ISBN (Electronic)9780791884256
DOIs
StatePublished - 2020
Externally publishedYes
EventASME 2020 15th International Manufacturing Science and Engineering Conference, MSEC 2020 - Virtual, Online
Duration: Sep 3 2020 → …

Publication series

NameASME 2020 15th International Manufacturing Science and Engineering Conference, MSEC 2020
Volume1

Conference

ConferenceASME 2020 15th International Manufacturing Science and Engineering Conference, MSEC 2020
CityVirtual, Online
Period9/3/20 → …

Keywords

  • Design for additive manufacturing
  • Dimensional accuracy
  • Fused filament fabrication
  • Warping distortion

ASJC Scopus subject areas

  • Safety, Risk, Reliability and Quality
  • Materials Science (miscellaneous)
  • Control and Optimization
  • Industrial and Manufacturing Engineering
  • Mechanical Engineering

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