Error compensation for fused deposition modeling (FDM) machine by correcting slice files

Purpose - The purpose of this research is to extend the previous approach to software error compensation to fused deposition modeling (FDM) machines and explores the approach to apply compensation by correcting slice files. Design/methodology/approach - In addition to applying the stereolithography (STL) file-based compensation method from earlier research; a new approach using the slice file format to apply compensation is presented. Under this approach, the confounded effects of all errors in a FDM machine are mapped into a virtual parametric machine error model. A 3D artifact is built on the FDM machine and differences between its actual and nominal dimensions are used to estimate the coefficients of the error functions. A slice file compensation method is developed and tested on two types of parts as a means for further improving the error compensation for feature form error improvement. STL file compensation is also applied to a specific FDM 3000 machine and the results are compared with those of a specific SLA 250 machine. Findings - The two compensation methods are compared. Although, the slice file compensation method theoretically allows higher compensation resolution, the actual machine control resolution of the FDM machine can be a limitation which makes the difference between STL compensation and slice file compensation indistinguishable. However, as the control resolution is increased, this method will make it possible to provide a higher degree of compensation. Originality/value - Compensation method applied to slice file format is developed for FDM machines and its limitations are explored. Based on the experimental study, dimensional accuracy of parts is considerably improved by the software error compensation approach.