Effect of Sparse-Build Internal Structure on Performance of Fused Deposition Modeling Tools Under Pressure

Two different approaches to design a sparse-build tool for fabrication by the fused deposition modeling (FDM) process are compared. One approach uses a 2D lattice structure and the other approach is inspired by topology optimization. Ultem 9085 is used as the material, and the amount of material used to build the tool is kept constant to ensure a fair comparison. A solid tool is also included in the comparison. The performance of the tool under uniform pressure is simulated using finite element analysis (FEA) and the accuracy of the FEA results is verified by comparing them with experimentally measured data for a similar tool. The build material, support material, build time, maximum displacement, and maximum von Mises stress are compared for the three build approaches, with an emphasis on the pros and cons of each sparse-build tool with regards to performance under uniform pressure and fabrication by FDM.