Predicting geometric errors and failures in additive manufacturing

Abstract

Purpose

Objects fabricated using additive manufacturing (AM) technologies often suffer from dimensional accuracy issues and other part-specific problems. This study aims to present a framework for estimating the printability of a computer-aided design (CAD) model that expresses the probability that the model is fabricated correctly via an AM technology for a specific application.

Design/methodology/approach

This study predicts the dimensional deviations of the manufactured object per vertex and per part using a machine learning approach. The input to the error prediction artificial neural network (ANN) is per vertex information extracted from the mesh of the model to be manufactured. The output of the ANN is the estimated average per vertex error for the fabricated object. This error is then used along with other global and per part information in a framework for estimating the printability of the model, that is, the probability of being fabricated correctly on a certain AM technology, for a specific application domain.

Findings

A thorough experimental evaluation was conducted on binder jetting technology for both the error prediction approach and the printability estimation framework.

Originality/value

This study presents a method for predicting dimensional errors with high accuracy and a completely novel approach for estimating the probability of a CAD model to be fabricated without significant failures or errors that make it inappropriate for a specific application.

Citation

Ntousia, M., Fudos, I., Moschopoulos, S. and Stamati, V. (2023), "Predicting geometric errors and failures in additive manufacturing", Rapid Prototyping Journal, Vol. 29 No. 9, pp. 1843-1861. https://doi.org/10.1108/RPJ-11-2022-0402