Quality Evaluation of Small Features Fabricated by Fused Filament Fabrication Method

The purpose of this research was to evaluate the quality of small features fabricated by the fused filament fabrication (FFF) method. The samples containing circular and square cross-sections through holes with different dimensions, lengths, and orientation angles were printed from ABS (acrylonitrile butadiene styrene) filament. The adopted optical inspection method allowed us to conduct observations of individual features and their measurements. The image processing software was used to determine the accuracy of the dimensions and shape of different cross-sections. Feret's diameters were used for the evaluation of shape accuracy by comparing them with theoretical dimensions assumed in a 3D CAD model. Considering the relationship between the real and theoretical dimensions of different features, general empirical equations for predicting the equivalent dimensions were developed. The proposed method of the quality evaluation of small features can be easily implemented and widely applied to other features, especially internal holes with different cross-sections made using various additive manufacturing methods.