Preliminary study on evaluation of printing parameters for a MEX repair application

Hybrid manufacturing, combining Additive Manufacturing (AM) and Subtractive Manufacturing (SM), represents a promising approach for the repair and upgrade of existing components produced via AM. In this context, repair applications with Material Extrusion (MEX) processes remain largely unexplored. The present work provides a preliminary study on the use of Fused Filament Fabrication (FFF) with a consumer-grade 3D printer as repairing tools for damaged or incomplete parts. While complete reprinting of a component is often considered the most straightforward option, repair can offer significant advantages in terms of material savings, time efficiency, and reduced energy consumption. Additionally, the process enables the integration of new geometries or functionalities, extending the original use of the component. This study sets the basis for MEX repair application by analyzing the printing parameters that have more influence on the repair process in terms of geometric deviation. Results show that the MEX-based repair process is highly dependent on printing temperature and material flow rate.