The Effect of Layer Thickness on Repeatability of 3d Printed PLA Parts Produced Using Openware 3D Printer

Abstract

Fused Filament Fabrication (FFF) is categorized as an additive manufacturing process, recognized as the simplest way to accomplish 3D printing. Previous studies have proven that FFF can be trusted to create custom parts with high complexity. However, some performance issues still exist with this method that must be resolved to improve conventional manufacturing techniques. One of them is its repeatability performance that is debatable when it comes to producing repetitive runs of similar parts. Printing parameter is one of the factors that play a significant role on the repeatability performance of parts produced. In this study, the effect of layer thickness on the repeatability of 3D printed PLA, produced using an Openware 3D printer (Espresso F220), was investigated. Two product geometries (Part A and Part B) were produced. Layer thickness was chosen as a variable parameter (0.1 mm, 0.2 mm, and 0.3 mm) for each geometry. Data to measure repeatability of the printed PLA parts were determined based on the measurements of length, width, thickness and surface roughness for each geometry. Then, repeatability performance was analyzed through One-way ANOVA analysis. From the results, the layer thickness parameter did influence dimensional quality and repeatability of samples produced. Part length and thickness offered better repeatability performance, to both product geometries being compared, in width and surface roughness. The study reveals that variations in sample properties depends on not only one, but also every printing parameter involved. Repeatability performance can be improved by identifying the ideal combination of printing parameters to produce good part quality.

ABSTRAK: : Fabrikasi Filamen Fius (FFF) yang dikategori sebagai proses pembuatan tambahan, diakui sebagai kaedah termudah bagi menghasilkan pencetakan 3D. Kajian terdahulu telah membuktikan bahawa FFF dapat menghasilkan komponen khas yang kompleks. Walau bagaimanapun, beberapa isu peningkatan mutu masih berlaku, iaitu kaedah ini masih perlu diperbetulkan bagi membaiki teknik pembuatan konvensional. Salah satu adalah peningkatan keterulangan bagi menghasilkan komponen yang serupa secara berulang. Parameter pencetakan adalah salah satu faktor yang berperanan penting bagi peningkatan keterulangan komponen yang dihasilkan. Kajian ini mengkaji tentang kesan ketebalan lapisan terhadap kebolehulangan PLA bercetak 3D yang dihasilkan melalui pencetak Openware 3D (Espresso F220). Dua geometri produk (bahagian A dan B) dihasilkan. Ketebalan lapisan dipilih sebagai parameter pemboleh ubah (0.1mm, 0.2mm dan 0.3mm) bagi setiap geometri. Data bagi mengukur keterulangan bahagian PLA yang bercetak ditentukan berdasarkan pengukuran panjang, lebar, ketebalan dan kekasaran permukaan bagi setiap geometri. Kemudian, peningkatan keterulangan dianalisa melalui analisis ANOVA Sehala. Dapatan hasil menunjukkan, parameter ketebalan lapisan mempengaruhi kualiti dimensi dan kebolehulangan sampel yang dihasilkan. Panjang dan ketebalan bahagian mempunyai peningkatan keterulangan yang lebih baik bagi kedua-dua geometri produk berbanding lebar dan kekasaran permukaan. Dapatan menunjukkan bahawa variasi sifat sampel tidak hanya bergantung pada satu, malah pada setiap parameter pencetakan yang terlibat. Peningkatan keterulangan dapat diperbaiki dengan mengenal pasti kombinasi parameter pencetakan yang ideal bagi menghasilkan kualiti bahagian terbaik.