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Characterization and control of primary natural frequency of FDM ABS prints through printer parameters and STL file manipulation

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Abstract

Fused deposition modeling (FDM) additive manufacturing (AM) printers frequently take significant trial and error to achieve desired dimensions, which has been fairly well investigated in the literature. What remains largely unexplored is the ability of a printer to match a desired primary natural frequency of a part. This can be critical when it comes to using printed parts as replacement parts in a moving system where a drastic change in a part’s natural frequency may appreciably change the dynamics of the system. This work uses iterative learning control (ILC) to create printed bars that match both desired dimensions and primary natural frequencies. Multiple case studies are presented and the best results were reprinted to investigate their repeatability and transferability. Dimensional error when using an ILC algorithm was comparable to that when deploying the default settings. Conversely, significant improvements in reducing warp and matching desired primary natural frequencies were found. These improvements were maintained when the output was printed on another machine in the same environment, indicating promise for deployment in a mass production setting. These results show that the presented ILC algorithm is capable of reducing error in both warp and desired primary natural frequency for simple parts on desktop FDM printers and lay the groundwork for further investigation with commercial grade and metal additive processes.

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Funding

This work was supported by two grants from the Ohio Space Grant Consortium (OSGC) Faculty Research Initiation Grant Proposal (FRIGP). Support was also provided by Ohio Northern University (ONU) summer research grants and Evans Fellowships (from ONU) supported the students involved in this project.

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Authors and Affiliations

  1. Mechanical Engineering Department, Ohio Northern University, 525 S Main St, Ada, OH, 48510, USA

    Lawrence W. Funke, Connor Lamison, J. Blake Hylton & Matthew N. Opara

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  1. Lawrence W. Funke
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  2. Connor Lamison
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  3. J. Blake Hylton
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  4. Matthew N. Opara
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All authors contributed significantly to the work in the order provided.

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Correspondence to Lawrence W. Funke.

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Funke, L.W., Lamison, C., Hylton, J.B. et al. Characterization and control of primary natural frequency of FDM ABS prints through printer parameters and STL file manipulation. Int J Adv Manuf Technol 129, 2139–2151 (2023). https://doi.org/10.1007/s00170-023-12378-x

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