Analysis of PLA Geometric Properties Processed by FFF Additive Manufacturing: Effects of Process Parameters and Plate-Extruder Precision Motion

The evolution of fused filament fabrication (FFF) technology, initially restricted to the manufacturing of prototypes, has led to its application in the manufacture of finished functional products with excellent mechanical properties. However, FFF technology entails drawbacks in aspects, such as dimensional and geometric precision, and surface finish. These aspects are crucial for the assembly and service life of functional parts, with geometric qualities lagging far behind the optimum levels obtained by conventional manufacturing processes. A further shortcoming is the proliferation of low cost FFF 3D printers with low quality mechanical components, and malfunctions that have a critical impact on the quality of finished products. FFF product quality is directly influenced by printer settings, material properties in terms of cured layers, and the functional mechanical efficiency of the 3D printer. This paper analyzes the effect of the build orientation (Bo), layer thickness (Lt), feed rate (Fr) parameters, and plate-extruder movements on the dimensional accuracy, flatness error, and surface texture of polylactic acid (PLA) using a low cost open-source FFF 3D printer. The mathematical modelling of geometric properties was performed using artificial neural networks (ANN). The results showed that thinner layer thickness generated lower dimensional deviations, and feed rate had a minor influence on dimensional accuracy. The flatness error and surface texture showed a quasi-linear behavior correlated to layer thickness and feed rate, with alterations produced by 3D printer malfunctions. The mathematical models provide a comprehensive analysis of the geometric behavior of PLA processing by FFF, in order to identify optimum print settings for the processing of functional components.