Edge quality in fused deposition modeling: I. Definition and analysis

Purpose – The purpose of this paper is to discuss the problem of the geometric accuracy of edges in parts manufactured by the Fused Deposition Modeling process, as a preliminary step for an experimental investigation. Methodology/approach – Three geometric variables (inclination, included and incidence angles) were defined for an edge. The influence of each variable on the geometric errors was explained with reference to specific causes related to physical phenomena and process constraints. Findings – Occurrence conditions for all causes were determined and visualized in a process map, which was also developed into a software procedure for the diagnosis of quality issues on digital models of the parts. Research limitations/implications – The process map was developed by only empirical considerations and does not allow to predict the amount of geometric errors. In the second part of the paper, experimental tests will help to extend and validate the prediction criteria. Practical implications – As demonstrated by an example, the results allow to predict the occurrence of visible defects on the edges of a part before manufacturing it with a given build orientation. Originality/value – In literature, the geometric accuracy of additively manufactured parts is only related to surface features. The paper shows that the quality of edges depends on additional variables and causes to be carefully controlled by process choices.