CAD Analysis of 3D Printed Parts for Material Extrusion—Pre-Processing Optimization Method

Free form fabrication (FFF), also known as fused deposition modeling (FDM), is a widespread and accessible method for prototyping. Parts a with lattice structure having functional roles as mechanism elements is becoming more common. In the research field, the mechanical characteristics as well as optimization methods for manufacturing these parts are major points of interest. One of the major aspects of FFF is part orientation during print, as it has influence over a wide range of variables, from tensile strength to surface quality and material consumption. For parts with a lattice structure, the printing orientation is important not only as a factor that influences the characteristics of the part itself, but also as a factor that determines the support requirements. However, due to the complex lattice structure, removing supports from these parts can be a challenging task. This study focuses on analyzing the reliability of available CAD optimization methods for FFF pre-processing. The analysis is performed using the Design for Additive Manufacturing module included in the Siemens NX software, version NX2406. The efficiency of CAD optimization was observed by taking into account the material consumption, printing times, surface quality, and support requirements. The study methods were based on the comparative analysis approach. The case studies used for the comparative analysis consider two-part inner structures: the solid structure approach with a rectilinear infill and the lattice structure approach.