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<p>Additive manufacturing (AM) processes enable the fabrication of customized and complex parts, such as lattices or porous structures. These structures offer advanced properties that are difficult to achieve with conventional manufacturing techniques. Complex geometries often require support structures to ensure stability during the printing process. The use of supports limits the AM’s capability to produce lattices because the removal is complicated or even impossible. Consequently, there is a growing focus on research and innovation aimed at achieving self-supporting structures for customized internal infill designs. This work examines the capability of fused filament fabrication (FFF) to manufacture millimeter-sized struts as elemental construction units of internal lattices. Specifically, we investigated the influence of material density <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\rho \)</EquationSource> <EquationSource Format="MATHML"><math> <mi>ρ</mi> </math></EquationSource> </InlineEquation>, overhang angle <InlineEquation ID="IEq2"> <EquationSource Format="TEX">\(\theta \)</EquationSource> <EquationSource Format="MATHML"><math> <mi>θ</mi> </math></EquationSource> </InlineEquation>, and strut diameter <i>D</i> on the quality (dimensional and geometrical tolerances) of the printed struts. The use of main effect plots, a nonparametric statistical method, and a factor ranking procedure to analyze the tolerance estimations performed by means of optical techniques yielded that <InlineEquation ID="IEq3"> <EquationSource Format="TEX">\(\theta \)</EquationSource> <EquationSource Format="MATHML"><math> <mi>θ</mi> </math></EquationSource> </InlineEquation> is the most critical parameter regarding dimensional tolerances and roughness. On the other hand, <InlineEquation ID="IEq4"> <EquationSource Format="TEX">\(\rho \)</EquationSource> <EquationSource Format="MATHML"><math> <mi>ρ</mi> </math></EquationSource> </InlineEquation> proved to be the key factor for parallelism and straightness, while <i>D</i> influences straightness and roughness.</p>

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Tolerance of lattice struts manufactured without supports via fused filament fabrication

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年6月27日

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  • Laura Robles-Lorite,
  • Alberto García-Collado,
  • Eloísa Torres-Jiménez,
  • Rubén Dorado-Vicente

摘要

Additive manufacturing (AM) processes enable the fabrication of customized and complex parts, such as lattices or porous structures. These structures offer advanced properties that are difficult to achieve with conventional manufacturing techniques. Complex geometries often require support structures to ensure stability during the printing process. The use of supports limits the AM’s capability to produce lattices because the removal is complicated or even impossible. Consequently, there is a growing focus on research and innovation aimed at achieving self-supporting structures for customized internal infill designs. This work examines the capability of fused filament fabrication (FFF) to manufacture millimeter-sized struts as elemental construction units of internal lattices. Specifically, we investigated the influence of material density \(\rho \) ρ , overhang angle \(\theta \) θ , and strut diameter D on the quality (dimensional and geometrical tolerances) of the printed struts. The use of main effect plots, a nonparametric statistical method, and a factor ranking procedure to analyze the tolerance estimations performed by means of optical techniques yielded that \(\theta \) θ is the most critical parameter regarding dimensional tolerances and roughness. On the other hand, \(\rho \) ρ proved to be the key factor for parallelism and straightness, while D influences straightness and roughness.