A challenge for enhancing the dimensional accuracy of a low-cost 3D printer by means of self-replicated parts

Owing to the lack of optimization, the dimensional accuracy of low-cost 3D printers is quite limited. In order to enhance the performances of a Prusa i3 3D printer, an optimization challenge was assigned to the students of the Specializing Master in Industrial Automation of the Politecnico di Torino. The enhancements were applied to four printers by manufacturing new self-replicated parts by means of the same 3D printers. Finally, a benchmarking activity was used to check and validate the results of the optimization activities. The benchmarking involved the fabrication of replicas of an innovative reference artifact by means of the modified printers. A coordinate measuring machine (CMM) was then used to inspect the dimensions of the replicas. Measures were used to compare the performances of the four optimized printers in terms of dimensional accuracy using ISO IT grades. The form errors of the geometrical features of the replicas were also evaluated according to the GD&T system. The benchmarking results show that the most effective modifications to the original printer were those related to the improvement of the structure stiffness and chatter reduction.