Abstract

In the present paper, we address the influence of print orientation angle on surface roughness obtained in lateral walls in fused deposition modelling (FDM) processes. A geometrical model is defined that considers the shape of the filaments after deposition, in order to define a theoretical roughness profile, for a certain print orientation angle. Different angles were considered between 5° and 85°. Simulated arithmetical mean height of the roughness profile, Ra values, were calculated from the simulated profiles. The Ra simulated results were compared to the experimental results, which were carried out with cylindrical PLA (polylactic acid) samples. The simulated Ra values were similar to the experimental values, except for high angles above 80°, where experimental roughness decreased while simulated roughness was still high. Low print orientation angles show regular profiles with rounded peaks and sharp values. At a print orientation angle of 85°, the shape of the profile changes with respect to lower angles, showing a gap between adjacent peaks. At 90°, both simulated and experimental roughness values would be close to zero, because the measurement direction is parallel to the layer orientation. Other roughness parameters were also measured: maximum height of profile, Rz, kurtosis, Rku, skewness, Rsk, and mean width of the profile elements, Rsm. At high print orientation angles, Rz decreases, Rku shifts to positive, Rsk slightly increases, and Rsk decreases, showing the change in the shape of the roughness profiles.

Highlights

  • In the fused deposition modelling (FDM) process, a filament is heated and the material is deposited by a nozzle onto a printing bed

  • The aim of the present paper is to define a geometrical model for surface roughness in lateral walls, in FDM printing processes

  • This paper presents a geometrical model for the simulation of roughness profiles obtained with different print orientation angles in FDM processes, in order to determine the mean height of the roughness profile, Ra

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Summary

Introduction

In the fused deposition modelling (FDM) process, a filament is heated and the material is deposited by a nozzle onto a printing bed. FDM printed parts are used in different applications, for example medical, electrical, aerospace, etc. It allows printing patterns for investment casting of biomedical implants [1]. Highly metallic-filled conductive composites can be prepared by FDM to be used in electromagnetic shielding, sensors, and circuit printing [2]. As for aerospace, carbon fiber reinforced PLA printed composites can be used [3]. FDM allows a wide range of materials, and the printed parts have effective mechanical properties

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