Dimensional and geometrical performance assessment of two FDM printers using a benchmark artifact

Additive Manufacturing (AM) is a promising process allowing the generation of complex geometries in near net shape. Standards are under development in a joint effort between ASTM and ISO to facilitate the use of AM processes in the industry. However, some areas of interest, for assessing dimensional and geometrical performances of AM printers, are still not covered.
In this article, dimensional and geometrical performances of two Fused Deposition Modelling (FDM) printers with Cartesian architecture (Ultimaker S3 and Intamsys FUNMAT HT) are compared using an original benchmark artifact design. Five parts were printed on each printer in ABS. Five other parts were also produced with the Ultimaker S3 in PLA to show the influence of material choice on the printer’s dimensional and geometrical performances. Intervals of tolerances (IT) were determined using the ISO 286-1 method.
Both machines can lead to an IT between 10 and 15 depending on the size of the measured features. In terms of geometrical deviations, coaxiality was the highest deviation observed on both printers with average values between 0.376 mm and 0.679 mm for the Ultimaker S3 in PLA and ABS, while the FUNMAT HT can reach values of 0.759 mm in ABS.
The FUNMAT HT exhibits a better homogeneity of computed IT according to its X and Y axes, while lower performances according to the Z axis were observed compared to the Ultimaker S3. In terms of geometrical performances, the FUNMAT HT has a lower ability than the Ultimaker S3 to reproduce features according to the Z axis. Except for this category, other geometrical features were more accurately reproduced with the Intamsys printer on a global level. The material choice also has a slight influence both on the dimensional and geometrical performances of the Ultimaker S3.