THE INFLUENCE OF THE INPUT PARAMETERS TO THE DIMENSIONAL ACCURACY OF

THE 3D PRINTED PROTOTYPE

Obrad SPAIĆ
Aleksandra KOPRIVICA
Mirjana JOKANOVIĆ
Srđan ĆURIĆ

Abstract: The key of a success, in making the physical prototypes of a good accuracy, is certainly a
technology of a rapid prototyping (RP - Rapid Prototyping), by which are, relatively rapidly and
inexpensive, produced different classes of a prototype. The RP technology implies a sequence of
technological procedures which enable direct production of a complex of physical objects. The digital 3D
geometric models are used as inputs. They may be prepared using a CAD program or a technology of a
3D scanning of the existing object and the subsequent treatment of the scanning results. One of the RP
technologies, which is prepared by adding a physical model of the material, layer by layer, is 3D
printing. Whereas, in 3D printing, the thickness of a layer is selected depending on the desired accuracy
of the prototype, this paper analyses the influence of the thickness of the 3D printer to the dimensional
accuracy of the prototype, in case when the prototyping is based on the CAD model.

Key words: 3D printer, dimensional accuracy, prototype.

intended for various kinds of tests, testing and use,

1. INTRODUCTION depending on the characteristics of the prototype and the
areas of the implementation of the newly-developed
The increasing market globalization, as well as the products/systems [1].
constant acceleration of the technical - technological For centuries it was thought that the design of a particular
progress require from companies increased flexibility in product is confirmed with the production of its physical
product design. It is essential that companies are oriented model of the prototype. However, at the present time,
to continuous innovation and the creation of new, or fabrication of the prototype, as an important part of the
changes of the existing products. product development process, comprise the activities of
In the context of the product development, certainly the the design, optimization and simulation on the computer
most important place takes a phase of the prototype and also creating a real, tangible and functional part
production, where the model of the desired product is (physical prototype). On one side, there are virtual
made, very representative, with high quality and the prototypes, which are studied and analyzed, while on the
possibilities of testing the characteristics. other hand, there is a physical model of the product,
Although the benefits of 3D printing are at a high level, which is used for testing and experiments [2].
one of the perceived flaws would be dimensional Methods for the production of a physical prorotype can be
accuracy, that is, the deviation of the starting model, from classified into three groups [3]:
the CAD software, to the produced prototype, which was  traditional methods (manual and mechanical),
analysed in this paper.  rapid prorotyping and
 others.
2. THE PROTOTYPE AND THE METHODS
OF ITS PRODUCTION The greatest significance of the traditional method is the
ability to create prototypes of the materials that will be
Word prototype represent a derivate of the Greek words used for the production. Traditional methods have some
“protos” = first and “tipos” = impression of “prototipon” limitations, as for example: the time required for the
= primitive form. Accordingly, a general definition could production of the prototypes, the problems in making a
be formed as follows: The prototype is the first or original complex object, a large amount of manual labor, a wide
copy of something that is or will be reproduced or variety of technical and practical knowledge which are
developed. However, given the widespread use of the necessary for the prototypes’ production [3].
prototype concept in practice, the following Rapid prototyping is a general name for several similar
comprehensive definition also could be used: A prototype technologies which produce physical prototypes directly,
is a first, the original shape, type, example of the from CAD files or other digitized data by layered
product/system or of its part in an appropriate form, application of the building material [3].

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2.1. Rapid Prototyping
The characteristics of the previous mentioned
The term rapid prototyping (RP) refers to a series of
technologies are given in the following table.
similar manufacturing processes by which are automatic,
with successive application and with bonding layers of
Table 1: The characteristics of the RP technologies [3]
building materials, based on the control instruction
RP
created directly from CAD files or other digital data TECHNOLOGY
SLA SLS FSM 3DP
without the use of tools, equipment, without the need for Maximum size
510x510x610 380x330x460 610x510x610 510x610x410
additional machining operations, produced physical (mm)
Layer thickness
objects [1]. (mm)
0,05-0,3 0,08-0,2 0,05 0,013-0,3
The process of applying the layers of the building Accuracy (mm) 0,1-0,01 0,03-0,38 0,127-0,254 0,025-0,356
material is commonly performed in a horizontal xy plane,
Speed, price
while the process of interconnecting the layers of the Size and Accuracy and Price and and possibility
Advantages
building material is performed in a vertical z plane [1]. accuracy materials materials of making a
model in color
The overall process may be viewed through the 3 phase Post-
[3]: processing Size, weight
Stability of
 pre-processing, Disadvantages and liquid and the price Speed
the model
working of the system
 direct production of prototypes and materials
 post-processing.

Since the advantages of RP technology are extremely 2.1.1. 3D Printing

huge, it has resulted in the rapid development, so today The work of these systems is based on chemical bonding,
we can speak about the tree of RP technologies. A adhesive liquids - binder, powdered building materials,
common feature of all technologies is to use method of whereby physical objects are printed, directly from the 3D
preparation of layer by layer, and depending on which CAD environment [4].
material is used (liquid, solid, powder), they all may be The figure 1. illustrates the method of making one layer.
divided into 2 groups [3]: The following sections should be noted on the schematic
1. Techniques of materials addition, for building the view: on the left side there is a dust storage and a piston
physical model, layer by layer. Within this group for adding material. The roller is shown as a circle, along
there are a number of techniques but those that are which is a moving bridge represented as a square. In the
commonly used in practice are: Stereolithography middle, there is a working chamber with a platform and
(SLA), Selective Laser Sintering (SLS), Modeling of on the right there is a hole for accepting the surplus of the
the Deposit of Molten Material (FSM), 3D Printing material. The bridge can move in both directions and the
(3DP). head moves along the bridge. This makes the possibility
2. The material removal processes, such as milling, for applying the binder in a horizontal plane [5].
which removes the excess material from the block of
spatial model, thereby producing the desired physical
model.

Fig. 1: 3D Printing procedure [5]

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In the first operation, the moving bridge, which carries the
roller and the print head, moves from left to the right. The
roller rotates in the direction shown in (1) and takes away
certain quantity of powder. Then, in the second step (2),
this powder is drawn into a thin layer over the previously
made layer on the platform of the working chamber. At
the end of the walk to the right (3), the roller takes away
the excess of the powder to the opening that accepts it and
enters the repository. In the next step (4), the bridge
moves from right to the left, and in the same time the
nozzle on the print head of the syringe binds the
appropriate points of the current cross-section and thus
forms the liquid layer of the model. When the bridge
arrives in the extremly left position (5), the piston for
adding the material is raised by one step, while the
platform is lowered by the thickness of the layer and Fig. 2: ZPrinter 450 [7]
everything is ready for the re-cycle [5].
Dust to which no binding agent is applied serves as a
aupport. When the process is completed, the finished part
is in unbound powder. The platform of the working
volume is lifted and the part is removed from the excess
powder. The excess material is sucked in and sifted and
reused for the next model [5].
The produced prototype, removed from the machine
working chamber can be applied for a limited use, while
for the full use it is necessary to perform post-processing.
Post-processing operations are reduced to the infiltration
of the prototype by the appropriate means (wax,
cyanoacrylate, two-component epoxy resin, etc.). blasting,
painting, lacquering and metallizing for a better visual
effect. By adding these agents, the prorotype improves
mechanical properties and ensures elasticity, all in
accordance with the requirements and needs of the
customer [5]. Fig. 3: 2D model

3. EXPERIMENTAL RESEARCH

3.1. The prototype production on the ZPrinter

450
The ZPrinter 450 features the latest features that automate
and simplify the 3D color printing process. Pleasant
design and simplicity, combined with high performance
composite materials, have made it possible to use this
printer widely. It is also important to emphasize that a
precise 450 DPI 3D color prototype model is obtained,
five to ten times faster than the others printer for the same
purpose. The appearance of the printer is shown in the
next figure 2 [6].
The ZPrinter 450 offers the ability to print prototypes of
products of various designs, relief maps, human hearts,
architectural models (in order for construction workers to
have a cleaner picture of design plans, etc.), which puts it
on the list of one of the most reliable and high quality
printers. The biggest advantage is certainly the ability to Fig. 4: 3D model
print the prototypes in color [6].
The experiment was done in the laboratories at the Since there are many factors that can have a different
Production and Management Faculty Trebinje. effect on achieving the accuracy of prototype production,
Workshop drawing of the object, i.e. the 2D model was it is important to emphasize that the printing was done in
developed using the AutoCad 2013 software (figure 3). the function of varying the thickness of the layer.
Based on the 2D model, the 3D model, shown in the The constructed 3D model is converted into a STL file,
figure 4, was also created. after which the models, with the different layers’
thickness were made.

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The size of the layers’ thicknesses and number of layers
for each model is given in the table 2.
Figure 5 shows produced models.

Table 2: The size of the layers’ thickness and number of

layers
MODEL MODEL MODEL MODEL
1 2 3 4
Layers’
1.250 1.125 1 0.875
thickness
Number
78 87 98 112
of layers

Fig. 6: Height’s positions

Fig. 5: Produced models

Time, required, for all produced models is given in the Fig. 7: Length’s positions
following table 3.

Table 3: The total required time for models’ production

TIME [min]
OPERATION Model
1 2 3 4
Pre-processing 10 10 10 10
Direct
35 40 45 50
production
Post-
50 50 50 50
processing
TOTAL 95 100 105 110

After the models were made, they were accessed by

measurement, i.g. their height (h=35 mm ), length (l=40
mm) and thickness (s= 10 mm).
Positions, at which the measurement was done, are shown Fig. 8: Thickness’s positions
in the next figures (figure 6, figure 7, figure 8).
At every position, the dimensions were measured three Using Microsoft Excel, while analyzing the data and
times and after that their average values were used for the layer’s thicknesses, certain dependences were made.
analyses. The deviation of the workpieces’ thickness, depending on
the thickness of the layer, is shown in the figure 9. From
the diagram, it can be seen that, contrary to expectation,
the deviation is greatest at the lowest value of the
thickness of the layer and it decreases with the increasing
the layer’s thickness.

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 Of all geometric dimensions, the slightest deviation from
the nominal measure, depending on the layer’s thickness,
is the angle deviation, which is shown in the diagram in
the figure 12. The diagram shows that the deviation is
minimum at the smallest value of the layer’s thickness
and that it first grows and then decreases, with the
increasing the layer’s thickness.

Fig. 9: Dependence of the thickness of the objects from

the layer’s thickness

The deviation of the height of the workpiece, depending

on the layer’s thickness, is shown in the figure 10. The
diagram shows that the minimum deviation is at the
minimum thickness of the layer and that it grows as the
thickness of the layer increases. It is interesting to note
that the deviation of the workpieces’ height at a layer’s
thickness of 1.125 mm is less than the deviation at a Fig. 12: Dependence of the angle’s value from the layer’s
layer’s thickness of 1 mm and 1.250 mm. thickness

4. CONCLUSION
The emergence of 3D printing technologies has already
been declared by many as the third industrial revolution,
as well as the technologies that will surely mark the 21 st
century. 3D printing solutions offer the ability to produce
very complicated shapes of products and tools in a
relatively short period of time, only based on 3D model of
the product or tool design. Geometric shapes, which can
not be achieved with conventional production
technologies, do not pose any problems for 3D printing.
In addition, 3D printing also allows the creation of a
whole assembly made of parts, which are actually made
as one product, so that the installation operation is
Fig. 10: Dependence of the height of the objects from the missing.
layer’s thickness Based on 3D prints, future products can be analyzed more
The deviation of the length of the workpiece, depending efficiently, as well as avoiding potential bugs on products,
on the layer’s thickness, is shown in the figure 11. The that, based on a 3D computer model, could not be spotted.
diagram shows that the deviation is minimum at the Previously said saves both, time and money.
smallest value of the layer’s thickness and that it first From the analyses carried out, it can be concluded that the
grows and then decreases, with the increasing the layer’s deviations of the geometric values from the nominal
thickness. measure significantly depend on the thickness of the
powder’s layer. Thus, when creating work items on a 3D
printer, the thickness of the powder’s layer should be
selected depending on the required accuracy of the
geometric dimensions.

REFERENCES
[1] TOPČIĆ, A., TUFEKČIĆ, Dž., CERJAKOVIĆ, E.
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Fig. 11: Dependence of the length of the object from the prototipa, Univerzitet u Tuzli, Mašinski fakultet u
layer’s thickness Tuzli, Tuzla

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proizvoda sa posebnim osvrtom na fazu izrade
prototipa, Zbornik radova Infoteh Jahorina 2016,
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CORRESPONDANCE
Obrad SPAIĆ, Ass. Sc.
University of East Sarajevo
Faculty of the Production and
Management
Stepe Stepanovića
89 101 Trebinje, Bosnia and Herzegovina
obradspaic59@gmail.com

Aleksandra KOPRIVICA, degree in

Industrial Engineering and Management
University of East Sarajevo
Faculty of the Production and
Management
Stepe Stepanovića
89 101 Trebinje, Bosnia and Herzegovina
aleksandra.koprivica@ymail.com

Mirjana JOKANOVIĆ, degree in

Industrial Engineering and Management
University of East Sarajevo
Faculty of the Production and
Management
Stepe Stepanovića
89 101 Trebinje, Bosnia and Herzegovina
jokanovic.mirjana1@gmail.com
Srđan ĆURIĆ, degree in Industrial
Engineering and Management
University of East Sarajevo
Faculty of the Production and
Management
Stepe Stepanovića
89 101 Trebinje, Bosnia and Herzegovina
srdjancuric@gmail.com

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