Errors in different geometric aspects of common engineering parts during rapid prototyping using a Z Corp 3D printer

Abstract

The aim of this paper is to analyse dimensional errors and repeatability of commonly used engineering parts, including a metric bolt, a gear and a shaft, produced by rapid prototyping. The parts were designed by a SolidWorks software package and printed by a ZPrinter 450 from Z Corporation where ZP150 powder and ZBond 90 infiltration were used. In most cases, the dimensional errors on produced parts were within acceptable limits. However, the process was determined to be unsuitable for features requiring very high dimensional accuracy and good surface finish. The influence of the stacking effect on the parts became significant in the case of longer parts and was proportional to the z axis dimension of a part. The accuracy and repeatability of a produced part depended on the part’s orientation. Dimensions in the z axis direction showed very good repeatability, but the accuracy decreased with the increase of length. On the other hand, the repeatability in the xy plane was not as good compared to the accuracy in the same plane.