Modeling fused filament fabrication machine height accuracy through layer thickness variation

Abstract

This thesis addresses the modeling and prediction of total height error of a 3D printed part using a layer-by-layer approach. Layer to layer thickness error is modeled across the build height of Polyactic acid (PLA) and Acrylonitrile butadiene styrene (ABS) parts. A height error compensation model is then formulated and applied at a G-code level to drive the machine to print accurate parts. Preliminary experimentation was done on New Valance Robotics' two fused deposition modeling machine versions, the NVPro and the NVPro High-temp. Results suggested that the layer thickness approach was a viable technique for predicting total part height error. The compensation model for PLA parts was also tested and the compensated parts were significantly closer to the expected part height than the uncompensated prints. However, further experimentation will need to be carried out to solidify a model for ABS parts. Recommendations for future work, measurement method improvement, and model applications are also discussed.