2024 ASEE Annual Conference & Exposition

Preliminary Investigation of Dimensional Accuracy of 3D-Printed PLA—A Project-Based Learning Experience (WIP)

Presented at Experiential Learning in ET Programs II

In the past decade, 3D printing has improved significantly and the use of 3D printed parts has extended to more precise industrial and scientific applications including space and medical applications. In subtractive Computer Numerical Control (CNC) machining, such as milling and Electro Discharge Machining (EDM), some tool offsets, applied through the G-code, are used during machining to compensate for the tool dimensions and to ensure the dimensions of the final machined product match the original designed CAD model. Similar techniques have been implemented in different 3D printers but they still experience dimensional inaccuracy. Some of these inaccuracies might be fixed by performing the proper calibration but others need further investigation. In this study, the author will investigate the dimensional inaccuracies in the 3D printing process and the printing parameters and configuration affecting them. These parameters include layer thickness, percentage infill, infill pattern, printing speed, printing temperature, and number of shells. The effect of some geometric aspects of the 3D printed products such as size, shape, orthogonality, curvature, and whether dimension is internal or external will be considered. A significant number of specimens will be prepared and analyzed with precision measurement tools to evaluate and characterize the dimensional inaccuracy. Offset parameters and/or dimensional compensations will be estimated based on the analysis of the results. These parameters are expected to guide users to scale or modify their model before printing to ensure they reach the desired accuracy in the printed product.

Authors

Dr. Ahmad Fayed http://orcid.org/https://0000-0001-9461-8861 Southeastern Louisiana University [biography]

Ahmad Fayed is an Associate Professor of engineering technology, and the holder of the Bell South endowed professorship in industrial and engineering technology at Southeastern Louisiana University (SELU). Ahmad completed his Ph.D. in Mechanical Engineering at University of Nevada Las Vegas (UNLV) and taught engineering classes at multiple schools including Al-Azhar University, King Saud University, University of Nevada Las Vegas (UNLV), University of Nevada Reno (UNR) and Purdue University Northwest (PNW).
Ahmad taught classes in different settings of instruction including online, blended, flipped, and technology-assisted classes. To increase student success, facilitate the instruction, enhance the level of engagement, assess student performance and evaluate his own teaching methods, Ahmad has been using innovative teaching approaches and utilizing several in-class activities and technology tools. Among the tools he has been using for in-class instant assessment and feedback, offline class interactions, and grading are iClickers, TopHat, Plickers, Kahoot, self-paced interactive PowerPoints, AnswerGarden, Piazza, CATME, Mentimeter, and Gradescope.
At multiple national conferences, Ahmad offered presentations and workshops in using technology in classrooms to enhance student engagement and facilitate assessment and grading. He enjoys interactive teaching and is constantly exploring and using new teaching styles and technology tools to make the knowledge transfer process as smooth as possible. His unique teaching approaches are always recognized by his students and colleagues and have resulted in 3 Outstanding Teaching awards.
His research interests include Engineering Education, Additive Manufacturing, Computer Vision, Robotics, Active Vibration Control, and Optimization.
www: http://bit.ly/ProfFayed
Research Gate: https://www.researchgate.net/profile/Ahmad-Fayed
LinkedIn: https://www.linkedin.com/in/ahmadfayed/

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