Learning-based error modeling in FDM 3D printing process

Purpose Additive manufacturing (AM) technologies are gaining immense popularity in the manufacturing sector because of their undisputed ability to construct geometrically complex prototypes and functional parts. However, the reliability of AM processes in providing high-quality products remains an open and challenging task, as it necessitates a deep understanding of the impact of process-related parameters on certain characteristics of the manufactured part. The purpose of this study is to develop a novel method for process parameter selection in order to improve the dimensional accuracy of manufactured specimens via the fused deposition modeling (FDM) process and ensure the efficiency of the procedure. Design/methodology/approach The introduced methodology uses regression-based machine learning algorithms to predict the dimensional deviations between the nominal computer aided design (CAD) model and the produced physical part. To achieve this, a database with measurements of three-dimensional (3D) printed parts possessing primitive geometry was created for the formulation of the predictive models. Additionally, adjustments on the dimensions of the 3D model are also considered to compensate for the overall shape deviations and further improve the accuracy of the process. Findings The validity of the suggested strategy is evaluated in a real-life manufacturing scenario with a complex benchmark model and a freeform shape manufactured in different scaling factors, where various sets of printing conditions have been applied. The experimental results exhibited that the developed regressive models can be effectively used for printing conditions recommendation and compensation of the errors as well. Originality/value The present research paper is the first to apply machine learning-based regression models and compensation strategies to assess the quality of the FDM process.