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<p>This study presents a compelling comparison between advanced multi-axis and traditional 3-Axis Fused Deposition Modeling (FDM) techniques in fabricating tubular polylactic acid (PLA) structures. Focusing on dimensional accuracy, surface finish, material usage, and print time, the research explores how a 5-Axis FDM system redefines additive manufacturing capabilities. Tubular models with solid cross-sections were fabricated using both methods: 5-Axis printing required no support structures, while 3-Axis printing relied on them. Detailed measurements—supplemented by microscopic and ImageJ-based analyses—revealed significant geometric advantages in the 5-Axis process, especially on curved and inclined surfaces. The 5-Axis approach reduced common issues such as the staircase effect and support-induced distortions, resulting in surface roughness improvements of up to 21%. Moreover, this method achieved dimensional accuracy with minimal planar deviations and eliminated the need for extensive post-processing. Material consumption dropped by as much as 31%, and printing times were cut by up to 48%, highlighting the efficiency of optimized multi-axis toolpaths. These findings emphasize the transformative potential of 5-Axis FDM for precision manufacturing, offering a more sustainable and efficient route to producing high-quality functional parts. The research underscores how rethinking print orientation and axis control can unlock new standards in 3D-printing performance.</p>

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Enhanced performance in additive manufacturing: a comparative study of multi-axis and 3-axis FDM for tubular parts

  • 期刊论文

  • 发表日期：

    2025年7月4日

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  • Ali Fathi,
  • Mehran Mahboubkhah,
  • Amir Entezari Maleki,
  • Ahmet Dumlu,
  • Kağan koray Ayten,
  • Gürkan Kalınay

摘要

This study presents a compelling comparison between advanced multi-axis and traditional 3-Axis Fused Deposition Modeling (FDM) techniques in fabricating tubular polylactic acid (PLA) structures. Focusing on dimensional accuracy, surface finish, material usage, and print time, the research explores how a 5-Axis FDM system redefines additive manufacturing capabilities. Tubular models with solid cross-sections were fabricated using both methods: 5-Axis printing required no support structures, while 3-Axis printing relied on them. Detailed measurements—supplemented by microscopic and ImageJ-based analyses—revealed significant geometric advantages in the 5-Axis process, especially on curved and inclined surfaces. The 5-Axis approach reduced common issues such as the staircase effect and support-induced distortions, resulting in surface roughness improvements of up to 21%. Moreover, this method achieved dimensional accuracy with minimal planar deviations and eliminated the need for extensive post-processing. Material consumption dropped by as much as 31%, and printing times were cut by up to 48%, highlighting the efficiency of optimized multi-axis toolpaths. These findings emphasize the transformative potential of 5-Axis FDM for precision manufacturing, offering a more sustainable and efficient route to producing high-quality functional parts. The research underscores how rethinking print orientation and axis control can unlock new standards in 3D-printing performance.