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<p>In conventional FDM 3D printers, stair-stepping and ridge defects are always visible, and there is a need for support structures to print complex parts. In some cases, printing the part is not possible at all. This significantly affects surface integrity, especially the surface roughness of the parts. Furthermore, the use of supports leads to material waste and increased manufacturing costs, raw material consumption, and printing time. To tackle these challenges, 5-axis 3D printing has shown promising results. Previous works have quite thoroughly investigated the fabrication of 5-axis in delta or parallel 3D printers. After all, A lack of thorough and DOE-based investigation of 5-axis implementation in the most common and everyday-used FDM 3D printers which are cartesian types exist. A full factorial experimental design with two replicates was implemented with three main factors: process type at two levels: three and five degrees of freedom, part rotation angle at four levels: 22° 30′, 45°, 67° 30′, and 90°, and layer height at two levels: 0.2 and 0.4&#xa0;mm. In total, 32 samples were fabricated, and responses such as printing time, material consumption, surface roughness, and dimensional accuracy were analyzed. The analysis results indicate the decisive superiority of the five-axis process. This process succeeded in reducing printing time by up to 51.59% and raw material consumption by up to 81.46%, demonstrating a significant optimization in productivity and production costs. From a quality perspective, the five-axis process, by eliminating the need for supports, significantly improved the surface quality and integrity of the parts and reduced the surface roughness parameter (R<sub>a</sub>) by up to 63.68%. Furthermore, the dimensional accuracy assessment revealed that the samples produced with this process had much less deviation from the original 3D model and achieved perfect conformity under optimal conditions. In summary, this research shows that utilizing a five-degree-of-freedom system in FDM 3D printing is an effective solution for overcoming the limitations of conventional machines, leading to simultaneous improvements in speed, cost reduction, and a significant enhancement in the final quality and accuracy of complex parts.</p>

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Advancements in five-axis 3D printing for process and surface enhancement: optimizing cartesian FDM through DOE

  • 期刊论文

  • 发表日期：

    2026年4月15日

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  • Mohammadhossein Alinaghipour,
  • Hamed Adibi,
  • Seyed Mehdi Rezaei

摘要

In conventional FDM 3D printers, stair-stepping and ridge defects are always visible, and there is a need for support structures to print complex parts. In some cases, printing the part is not possible at all. This significantly affects surface integrity, especially the surface roughness of the parts. Furthermore, the use of supports leads to material waste and increased manufacturing costs, raw material consumption, and printing time. To tackle these challenges, 5-axis 3D printing has shown promising results. Previous works have quite thoroughly investigated the fabrication of 5-axis in delta or parallel 3D printers. After all, A lack of thorough and DOE-based investigation of 5-axis implementation in the most common and everyday-used FDM 3D printers which are cartesian types exist. A full factorial experimental design with two replicates was implemented with three main factors: process type at two levels: three and five degrees of freedom, part rotation angle at four levels: 22° 30′, 45°, 67° 30′, and 90°, and layer height at two levels: 0.2 and 0.4 mm. In total, 32 samples were fabricated, and responses such as printing time, material consumption, surface roughness, and dimensional accuracy were analyzed. The analysis results indicate the decisive superiority of the five-axis process. This process succeeded in reducing printing time by up to 51.59% and raw material consumption by up to 81.46%, demonstrating a significant optimization in productivity and production costs. From a quality perspective, the five-axis process, by eliminating the need for supports, significantly improved the surface quality and integrity of the parts and reduced the surface roughness parameter (Ra) by up to 63.68%. Furthermore, the dimensional accuracy assessment revealed that the samples produced with this process had much less deviation from the original 3D model and achieved perfect conformity under optimal conditions. In summary, this research shows that utilizing a five-degree-of-freedom system in FDM 3D printing is an effective solution for overcoming the limitations of conventional machines, leading to simultaneous improvements in speed, cost reduction, and a significant enhancement in the final quality and accuracy of complex parts.