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Investigation of the impact of power consumption, surface roughness, and part complexity in stereolithography and fused filament fabrication

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Abstract

Today, additive manufacturing (AM) is being utilized in a plethora of fields and applications. This study investigates two of the most commonly used AM technologies, fused filament fabrication (FFF) and stereolithography (SLA), under different part complexities and their effects to finished part quality. The process parameters investigated are infill density (ID), infill pattern (IP), and layer height (LH). The output variables observed are power consumption (PC), surface roughness (SR), and mass. Statistical analysis of experimental data indicates that LH is the most influential parameter for all output variables except mass. A validation study is later performed using three specimens with more diversely complex geometries. The model complexity is then evaluated and analyzed using three different ratios. Normalizing PC with respect to volume indicates a lower PC per unit volume for FFF. Experimental data also indicates SLA has a better surface finish and uses less power. This paper reports the state-of-the-art FFF and SLA process knowledge blocks created through this research study.

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Funding

This research was partially supported by the National Science Foundation Award 1801120, Smart Manufacturing for America’s Revolutionizing Technological Transformation.

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Authors and Affiliations

  1. Department of Mechanical Engineering, College of Engineering, Tennessee Tech University, Cookeville, TN, 38505, USA

    Mohammad Alshaikh Ali

  2. Department of Manufacturing and Engineering Technology, College of Engineering, Tennessee Tech University, Cookeville, TN, 38505, USA

    Ismail Fidan

  3. Department of Engineering Management and Technology, College of Engineering, University of Tennessee at Chattanooga, Chattanooga, TN, 37403, USA

    Khalid Tantawi

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  1. Mohammad Alshaikh Ali
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  2. Ismail Fidan
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Contributions

All three authors contributed to various portions of the research project, mostly, however, by Ismail Fidan. Methodology, experimentation, and analysis were mostly done by Mohammad Alshaikh Ali. The initial draft was written by Mohammad Alshaikh Ali; revised and finalized by Ismail Fidan and Khalid Tantawi. All the authors read and approved the final manuscript. The entire research project was managed by Ismail Fidan.

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Correspondence to Ismail Fidan.

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Ali, M.A., Fidan, I. & Tantawi, K. Investigation of the impact of power consumption, surface roughness, and part complexity in stereolithography and fused filament fabrication. Int J Adv Manuf Technol 126, 2665–2676 (2023). https://doi.org/10.1007/s00170-023-11279-3

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