Accuracy of FDM PLA Polymer 3D Printing Technology Based on Tolerance Fields

Fused deposition modelling (FDM) 3D printers have the highest annual growth of 21.15% in the field of 3D printing. FDM desktop 3D printers account for 23.69% of FDM printers. The major drawback of FDM desktop printers is product accuracy, which is particularly pronounced when dimensionally inaccurate and multi-part printed products need to be fit together into a functional assembly. The research presented in this paper aims to determine the accuracy limits of FDM 3D printers when producing elements for assembly using a 3D printer in a tolerance-fit system. A novel method of computer-aided design (CAD) based on ISO 286 and the systematic calibration procedure of 3D printers were presented to achieve the dimensional accuracy of 3D printed parts. For this purpose, a set of nominal dimensions within the clearance fit was selected, and various CAD models were created according to the ISO 286 system of limits and fits. The CAD Slicer software-3D printer interaction was systematically examined for the best hardware and software features. It was found that the Horizontal Expansion parameter should be 0.0 mm and the Hole Horizontal Expansion parameter should be 0.13 mm. The Linear Advance factor was found to be 25. The measurement results showed that the desired tolerance ranges, system, and type of clearance fit could be achieved with a desktop 3D printer. The roundness tolerance for all clearance fits and shaft tolerance ranges in the hole base system was determined to join the parts into a clearance fit.