An Exploratory Study on the Accuracy of Parts Printed in FDM Processes from Novel Materials

The paper describes the experiment of assessing the chosen geometric characteristics of test models with simple geometry, shaped by the FDM (fused deposition modelling) method of different materials. The influence of the material grade and the degree of infill density on the shrinkage affecting their dimensional deviations and selected surface topography parameters of printed parts was examined and compared. Three different types of materials were used to fabricate the test models, namely HDGLASS and NANOCARBON, two new fibre reinforced composites available in the market and, additionally ABS, a popular monoplastic material. An infill density ratio of 10, 50 and 90% was assumed for each material. Three specimens were made on the same printer for each infill density, which allowed to assess the repeatability of the analysed characteristics. From among many possible shapes of models, a cube was chosen as representing the simplest geometry, facilitating the measurements themselves and the interpretation of the results. New fibre-reinforced materials are more attractive in industrial applications than pure plastics (ABS) due to their mechanical properties or appearance. They are characterized by a relatively low melting point and short cooling time, after which they can return to their original geometry; however, there is a lack of detailed data on the geometric accuracy of parts made of used composite materials. The presented work was to explanatorily broaden the knowledge about the properties of composite made parts. The practical purpose of the research was that on the basis of measurements, it would be possible to indicate among the materials used that particular material whose properties and method of application would allow obtaining the best quality surface and would be the most resistant to thermal loads. An attempt was also made to explain the possible causes of the differences in the observed characteristics of the tested materials.