Analysis of the Dimensional and Shape Accuracy and Repeatability of Models Produced in the Process of Additive Extrusion of Thermoplastic Polymers Using Fused Filament Fabrication Technology

To achieve high precision and repeatability of prototyped models, work is carried out to improve existing solutions and thus expand the areas of application of 3D printers. Ways to increase the efficiency of 3D printing are being sought. The subject of the work concerns the analysis of dimensional and shape accuracy and repeatability of samples produced by a technology based on layered extrusion of thermoplastic polymers using FFF—fused filament fabrication technology. The key parameter for assessing the quality of parts is the property most expected by 3D printer users regarding the accuracy of dimensions of manufactured prototypes. As part of the research, conclusions were drawn regarding the precision of the samples as original patterns. The dimensional accuracy in the x, y, and z axes of the 3D printer was determined in terms of the design of the 3D printer’s actuator system. Three-dimensional maps of deviations of the pattern surface were used in relation to the nominal 3D CAD model to test the accuracy. The analytical results obtained during the research work, together with the graphs of the normal distribution probability function, indicate a high repeatability for each of the axes, and the highest repeatability was for the z-axis. The dimensions in the remaining axes were within the assumed tolerance of 0.1 mm, except for the two extreme dimensions, which were caused by a different method of heat dissipation, proving the influence of the arrangement of samples on the working platform.