Minimizing Warpage for Macro-Size Fused Deposition Modeling Parts

In this study, we investigated warpage and corner lifting minimization for three-dimensional printed parts generated by macro-size fused deposition modeling (FDM). First, the reasons for warpage were theoretically elucidated. This approach revealed that the thermal deformation and differential volumetric shrinkage of the extruded molten plastic resulted in warpage of FDM parts. In addition, low adhesion between the deposited model and the heated or non-heated printing bed may intensify warpage further. As a next step, initial small-size and medium-size models were used to identify parameters to manage and minimize warpage in a way that would reduce material consumption and running time. Finally, a macro-size model was built to experimentally investigate and verify the technical solutions to minimize the warpage of FDM parts. In conclusion, an improved part with reduced warpage was efficiently produced after detailed consideration of thermal effects and adhesion force. Potential exists to widen the application scope of FDM technology in manufacturing for processes like thermoforming that involve mold core fabrication with heating. This technology, which has applications not only in mechanical engineering but also in related engineering fields, is convenient and could readily be applied to practical manufacturing industries.