Studies on profile error and extruding aperture for the RP parts using the fused deposition modeling process

Fused deposition modeling (FDM) is one of the leading rapid prototyping processes for producing acrylonitrile butadiene styrene prototypes. However, the extruding accuracy in part fabrication is subject to transmission machinery and filament diameter. The parts cannot be filled up completely. Therefore, profile error and extruding apertures are two substantial quality characteristics to be considered. This study proposed an original image measurement method for examining profile error through a series of standard cylinders laid on the contour of the part. Also, images captured can be used to identify non-filled regions on part appearance to calculate aperture area on the surface layer. Besides, this study investigated the effects of extruding parameters, including contour width, contour depth, part raster width, and raster angle, on quality characteristics by Taguchi’s method. A thin solid model based on a 2-D spiral was designed to demonstrate the proposed approach. Results of ANOVA and confirmation experiments showed that the parametric criteria concluded in this study could obtain satisfactory performances on profile error and extruding apertures in the FDM process.