Assessment of surface quality on textured FDM prototypes

Abstract

PurposeTest the detail resolution of fused deposition modeling (FDM) in the direct manufacture of rapid prototypes with textured surfaces.Design/methodology/approachA benchmark part carrying regular surface patterns with different feature sizes and aspect ratios has been manufactured on a FDM system with different build orientations. Layered parts have been inspected to detect the occurrence of quality defects on textured surfaces.FindingsThe experiments reveal the ability of currently available FDM systems to enhance prototype surfaces with form details on a millimeter scale. Results assist in identifying conditions which need to be satisfied in order to successfully reproduce generic texture geometries.Research limitations/implicationsAlthough the testing method can be applied to any layered manufacturing technique, results are limited to a specific process, and may be influenced by technical improvements of commercial fabrication systems.Practical implicationsA first contribution is given to a full feasibility assessment of direct texturing, which potentially appears as more responsive and cost‐effective solution than current post‐finishing practices.Originality/valueThe paper proposes a systematic approach to the manufacture of textured parts by rapid prototyping techniques. The analysis of surface appearance in the presence of small‐scale form details adds a novel aspect to current approaches to performance benchmarking, which typically focus on form errors and roughness of plain surfaces.