Toward cost-efficient tolerancing of 3D-printed parts: a novel methodology for the development of tolerance-cost models for fused layer modeling

Abstract Tolerance allocation methods significantly contribute to the qualification of Additive Manufacturing (AM) for (small-)series production ensuring high performance and efficiency. However, their usage prerequisites availability quantitative, reliable information on impact assigned tolerances resulting manufacturing costs. The given article proposes a novel methodology systematic development tolerance-cost curves cost-efficient tolerancing 3D-printed parts. proposed structured workflow aims at serving as general guideline both researchers practitioners, while exemplarily chosen perspective from Fused Layer Modeling (FLM) illustrates its adaption specific AM technology. indirect, non-apparent interrelations between costs are modelled with aid an activity-based cost model, whereas individual elements mapped function values machine-specific process parameters AM, e.g., layer height or printing speed, which required achieve design tolerances. total procedure covers all relevant steps, viz. identification quantification single items, benchmark artifacts, adapted measuring techniques, empirical determination data geometrical accuracy by experiments curves. Its exemplary application academic use case shows applicability benefits, but also current limitations.