Assessment of the Dimensional and Geometric Precision of Micro-Details Produced by Material Jetting

Additive Manufacturing (AM) technology has been increasing its penetration not only for the production of prototypes and validation models, but also for final parts. This technology allows producing parts with almost no geometry restrictions, even on a micro-scale. However, the micro-Detail (mD) measurement of complex parts remains an open field of investigation. To be able to develop all the potential that this technology offers, it is necessary to quantify a process's precision limitations, repeatability, and reproducibility. New design methodologies focus on optimization, designing microstructured parts with a complex material distribution. These methodologies are based on mathematical formulations, whose numerical models assume the model discretization through volumetric unitary elements (voxels) with explicit dimensions and geometries. The accuracy of these models in predicting the behavior of the pieces is influenced by the fidelity of the object's physical reproduction. Despite that the Material Jetting (MJ) process makes it possible to produce complex parts, it is crucial to experimentally establish the minimum dimensional and geometric limits to produce parts with mDs. This work aims to support designers and engineers in selecting the most appropriate scale to produce parts discretized by hexahedral meshes (cubes). This study evaluated the dimensional and geometric precision of MJ equipment in the production of mDs (cubes) comparing the nominal design dimensions. A Sample Test (ST) with different sizes of mDs was modeled and produced. The dimensional and geometric precision of the mDs were quantified concerning the nominal value and the calculated deviations. From the tests performed, it was possible to conclude that: (i) more than 90% of all analyzed mDs exhibit three dimensions (xyz) higher than the nominal ones; (ii) for micro-details smaller than 423 μm, they show a distorted geometry, and below 212 μm, printing fails.