Assessment of surface quality on textured FDM prototypes

Purpose - Test the detail resolution of fused deposition modeling (FDM) in the direct manufacture of rapid prototypes with textured surfaces. Design/methodology/approach - A benchmark part carrying regular surface patterns with different feature sizes and aspect ratios has been manufactured on a FDM system with different build orientations. Layered parts have been inspected to detect the occurrence of quality defects on textured surfaces. Findings - The experiments reveal the ability of currently available FDM systems to enhance prototype surfaces with form details on a millimeter scale. Results assist in identifying conditions which need to be satisfied in order to successfully reproduce generic texture geometries. Research limitations/implications - Although the testing method can be applied to any layered manufacturing technique, results are limited to a specific process, and may be influenced by technical improvements of commercial fabrication systems. Practical implications - A first contribution is given to a full feasibility assessment of direct texturing, which potentially appears as more responsive and cost-effective solution than current post-finishing practices. Originality/value - The paper proposes a systematic approach to the manufacture of textured parts by rapid prototyping techniques. The analysis of surface appearance in the presence of small-scale form details adds a novel aspect to current approaches to performance benchmarking, which typically focus on form errors and roughness of plain surfaces.