Improved accuracy of an FDM 3D printer using a face-diagonal length test using an artifact and a Vernier caliper

Abstract

PurposeThe purpose of this study is to improve the accuracy of a fused deposition modeling three-dimensional (3D) printer by identifying and compensating for position-independent geometric errors using a face-diagonal length test featuring a designed artifact and a Vernier caliper.Design/methodology/approachAn artifact that does not require support when printing was designed and printed to allow performance of the face-diagonal length test. A Vernier caliper was used to measure the lengths of diagonals in the XY, YZ and ZX planes of the printed artifact specimen; this completed the face-diagonal length test. The relationships between position-independent geometric errors of the linear axes X, Y and Z and the measured diagonal lengths of the three planes were determined to identify geometric errors.FindingsThe approach was applied to a commercial fused deposition modeling 3D printer, and three position-independent geometric errors were rapidly identified. The artifact was re-printed after model-based compensation for these errors and the diagonal lengths were re-measured. The results were verified via coordinate measuring machine measurement of a simple test piece without and with model-based compensation for identified geometric errors. Furthermore, the proposed approach was applied to a commercial 3D printer.Research limitations/implicationsThe measured diagonal lengths of the printed artifacts varied greatly. Thus, further studies should investigate the effects of printing materials and parameters on the length discrepancies of 3D printed artifacts.Practical implicationsA software-based compensation of identified position-independent geometric errors has to be used at commercial 3D printers for accuracy improvements of printed parts.Originality/valueThus, the approach is of practical utility; it can be periodically used to identify position-independent geometric errors and ensure that the 3D printer is consistently accurate.