Effect of 3D Printing Orientation on the Accuracy and Surface Roughness of Polycarbonate Samples

The study evaluates models produced using fused deposition modeling (FDM) technology in five orientations, fabricated from polycarbonate (PC) material with a FORTUS 360mc printer. The models included simple shapes (planes and cylinders) and complex free-form surfaces. Accuracy was assessed using a GOM Scan 1 scanner and GOM Inspect 2019 software, focusing on 3D deviations and dimensional and geometric deviations (form, position, and orientation, which have not yet been analyzed in similar studies and may limit the usage of the printed elements). Surface roughness was analyzed using a MarSurf XR profilometer, measuring Ra and Rz parameters. All models were characterized by a predominance of negative 3D deviations. The analysis of variance showed no effect of model orientation on the values of linear dimensional deviations and geometric deviations. The largest deviations were negative and associated with the size of the models. The average value of the absolute deviation of linear dimensions associated with the size of the model was 0.30 mm. The average value of the absolute deviation of other linear dimensions was 0.07 mm. The average value of orientation and position deviations for each model varied in the range of 0.15-0.20 mm, and for form deviation 0.16-0.20 mm. One of the models had a higher surface roughness (Ra = 17.2 mu m, Rz = 71.3 mu m) than the other four models (Ra in the range of 12.7-13.8 mu m, Rz in the range of 57.2-61.2 mu m). During the research, three distinct surface types were identified on the models. The research indicated the validity of taking surface type into account when analyzing its microgeometry.