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
The increasing market globalization, as well as the
constant acceleration of the technical - technological
progress require from companies increased flexibility in
product design. It is essential that companies are oriented
to continuous innovation and the creation of new, or
changes of the existing products.
In the context of the product development, certainly the
most important place takes a phase of the prototype
production, where the model of the desired product is
made, very representative, with high quality and the
possibilities of testing the characteristics.
Although the benefits of 3D printing are at a high level,
one of the perceived flaws would be dimensional
accuracy, that is, the deviation of the starting model, from
the CAD software, to the produced prototype, which was
analysed in this paper.
2. THE PROTOTYPE AND THE METHODS
OF ITS PRODUCTION
Word prototype represent a derivate of the Greek words
“protos” = first and “tipos” = impression of “prototipon”
= primitive form. Accordingly, a general definition could
be formed as follows: The prototype is the first or original
copy of something that is or will be reproduced or
developed. However, given the widespread use of the
prototype concept in practice, the following
comprehensive definition also could be used: A prototype
is a first, the original shape, type, example of the
product/system or of its part in an appropriate form,
depending on the characteristics of the prototype and the
areas of the implementation of the newly-developed
products/systems [1].
For centuries it was thought that the design of a particular
product is confirmed with the production of its physical
model of the prototype. However, at the present time,
fabrication of the prototype, as an important part of the
product development process, comprise the activities of
the design, optimization and simulation on the computer
and also creating a real, tangible and functional part
(physical prototype). On one side, there are virtual
prototypes, which are studied and analyzed, while on the
other hand, there is a physical model of the product,
which is used for testing and experiments [2].
Methods for the production of a physical prorotype can be
classified into three groups [3]:
 traditional methods (manual and mechanical),
 rapid prorotyping and
 others.
The greatest significance of the traditional method is the
ability to create prototypes of the materials that will be
used for the production. Traditional methods have some
limitations, as for example: the time required for the
production of the prototypes, the problems in making a
complex object, a large amount of manual labor, a wide
variety of technical and practical knowledge which are
necessary for the prototypes’ production [3].
Rapid prototyping is a general name for several similar
technologies which produce physical prototypes directly,
from CAD files or other digitized data by layered
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
we can speak about the tree of RP technologies. A
common feature of all technologies is to use method of
preparation of layer by layer, and depending on which
material is used (liquid, solid, powder), they all may be
divided into 2 groups [3]:
1. Techniques of materials addition, for building the
physical model, layer by layer. Within this group
there are a number of techniques but those that are
commonly used in practice are: Stereolithography
(SLA), Selective Laser Sintering (SLS), Modeling of
the Deposit of Molten Material (FSM), 3D Printing
(3DP).
2. The material removal processes, such as milling,
which removes the excess material from the block of
spatial model, thereby producing the desired physical
model.
The work of these systems is based on chemical bonding,
adhesive liquids - binder, powdered building materials,
whereby physical objects are printed, directly from the 3D
CAD environment [4].
The figure 1. illustrates the method of making one layer.
The following sections should be noted on the schematic
view: on the left side there is a dust storage and a piston
for adding material. The roller is shown as a circle, along
which is a moving bridge represented as a square. In the
middle, there is a working chamber with a platform and
on the right there is a hole for accepting the surplus of the
material. The bridge can move in both directions and the
head moves along the bridge. This makes the possibility
for applying the binder in a horizontal plane [5].

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
in the next figures (figure 6, figure 7, figure 8).
At every position, the dimensions were measured three
times and after that their average values were used for the
analyses.
Fig. 8: Thickness’s positions
Using Microsoft Excel, while analyzing the data and
layer’s thicknesses, certain dependences were made.
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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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
layer’s thickness of 1 mm and 1.250 mm.
Fig. 10: Dependence of the height of the objects from the
layer’s thickness
The deviation of the length of the workpiece, depending
on the layer’s thickness, is shown in the figure 11. 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. 11: Dependence of the length of the object from the
layer’s thickness
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. 12: Dependence of the angle’s value from the layer’s
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
missing.
Based on 3D prints, future products can be analyzed more
efficiently, as well as avoiding potential bugs on products,
that, based on a 3D computer model, could not be spotted.
Previously said saves both, time and money.
From the analyses carried out, it can be concluded that the
deviations of the geometric values from the nominal
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.
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prototipa, Univerzitet u Tuzli, Mašinski fakultet u
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[6] JOKANOVIĆ, M., KOPRIVICA, A. (2016) Razvoj
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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