Optimization of Cartesian and polar 3D printer structures using finite element analysis: a comparative study on material selection and design enhancement

This study explores the optimization of additive manufacturing (AM) configurations, specifically Cartesian and Polar 3D printers, by addressing challenges related to structural limitations, material weaknesses, and printing errors. Current research often lacks comparative analysis of material performance across different printer configurations, creating a gap in optimizing these systems. To address this, Finite Element Analysis (FEA) and experimental validation were employed to assess the suitability of carbon fibre and structural steel. Carbon fibre was found to be the optimal material for Cartesian printers due to its high strength-to-weight ratio and minimal deformation, with maximum deformation values of 0.12 mm in Cartesian and 0.18 mm in Polar printers, enhancing accuracy and reliability. For Polar printers, structural steel was selected for its stability and robustness, with deformation values of 0.45 mm in Cartesian and 0.62 mm in Polar configurations. Surface roughness analysis further supported these findings, with Polar printer specimens achieving a roughness of 1.464 µm using optimized gantry systems versus 1.895 µm with older systems, and Cartesian printer specimens showing 1.994 µm versus 2.125 µm. This research provides a detailed comparative analysis that enhances material selection and printer design optimization, contributing to improved AM processes and paving the way for future innovations in the field. The novelty of this study lies in its comprehensive approach to optimizing material selection across different 3D printing configurations, combining FEA with experimental validation.