Internal structure optimization for fused deposition modeling ABS parts

The production of massive parts with some additive technologies could be very expensive because of high production times. Research efforts to reduce the overall cost of Rapid Prototyping fabrication are oriented toward the development of cheaper equipment, the reduction of machining time, and the reduction of the cost and the amount of materials used. The maximum feed rate and the type of material are normally fixed by physical limits of the processes. In this paper the authors propose to reduce the fabrication time related to Fused Deposition Modeling (FDM) parts, decreasing the average density of prototypes using an internal narrow-waisted structure. In order to characterize and study the behavior of the obtained low density parts, an experimental plan has been prepared and performed. The process features a reduction of material used, time required, and reduces the economic and environmental costs. In order to characterize and study the behavior of the obtained low density parts, an experimental plan has been prepared, executed and analyzed. The mechanical properties of low density specimens have been tested, varying several factors such as raster density, slice height, volume reduction. The approach has been tested on fused deposition modeling prototypes ABS, but is general and can be applied on other kinds of technologies characterized by slow building of massive parts.