Error modeling and compensation for FDM machines

Purpose The purpose of this paper is to improve the accuracy of fused deposition modeling (FDM) machines. Design/methodology/approach An integrated error model and compensation methods are developed to improve the accuracy of FDM machines. The effects of machine-dependent and process-dependent errors are included in this integrated model. The error model is then used to obtain compensated values for the printed object. A three-dimensional artifact is designed for the FDM machine characterization. This process takes place only once and an error model for the machine is then developed. An artifact is designed that is feature rich and its coordinates are measured by the coordinate measuring machine (CMM). The CMM digitized values for the three-dimensional artifact are used to calculate the coefficients of the model. The integrated error model of the machine can be used to obtain the compensated values for any given part models. The coefficients of the integrated error model are machine-dependent and represent machine error estimation. To demonstrate this, two test examples are used and modified based on the machine model to verify the effectiveness of the proposed method. Findings The errors from machine mechanical structure and process are evaluated. The variation trend of each error is analyzed. The uncompensated and compensated models are compared, and the effectiveness of the integrated error model and compensation method is analyzed and validated. Originality/value An effective integrated error model with compensation is developed, which can be used to improve the FDM machines accuracy.