Minimizing warpage of ABS prototypes built with low-cost fused deposition modeling machine using developed closed-chamber and optimal process parameters

• Published in: International journal of advanced manufacturing technology 2019-03, Vol.101 (1-4), p.593-602
• Main Authors: Kuo, Chil-Chyuan, Wu, Yu-Ren, Li, Meng-Hong, Wu, Hao-Wei
• Format: Article
• Language: English
• Subjects: ABS resins; Acrylonitrile butadiene styrene; CAE) and Design; Chambers; Computer-Aided Engineering (CAD; Construction costs; Deposition; Engineering; Fused deposition modeling; Industrial and Production Engineering; Low cost; Mathematical models; Mechanical Engineering; Media Management; Modelling; Nozzles; Original Article; Process parameters; Prototypes; Rapid prototyping; Taguchi methods; Three dimensional models; Verification; Warpage
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-018-2969-7

Fused deposition modeling (FDM) is a well-known technology that is capable of fabricating three-dimensional prototypes with very complex geometries. However, the physical model built with acrylonitrile butadiene styrene (ABS) filament using a low-cost FDM machine is not satisfactory for most general engineering purposes due to warpage. Thus, minimizing the warpage of the ABS prototypes built with a low-cost FDM machine is a promising research issue. In this study, a closed chamber was designed and constructed to maintain the chamber temperature and increase the modeling space. It was found that the modeling space was increased by approximately 2.75 times. The optimal process parameters for reducing the warpage of ABS prototypes were also investigated using the Taguchi method. The dominant factor affecting the warpage of ABS prototypes is the bed temperature, followed by chamber temperature. The optimal process parameters for reducing the warpage of ABS prototypes are nozzle temperature of 230 °C, bed temperature of 93 °C, print speed of 60 mm/s, and chamber temperature of 43 °C. The optimal process parameter was also evaluated via the verification test. The optimal process parameters were also examined experimentally by a verification test.