Can the Dimensional Optimisation of 3D FDM-Manufactured Parts Be a Solution for a Correct Design?

Additive manufacturing technology, also known as 3D printing, has emerged as a viable alternative in modern manufacturing processes. Unlike traditional manufacturing methods, which often involve complex mechanical operations that can lead to errors and inconsistencies in the final product, additive technology offers a new approach that enables precise layer-by-layer production with improved geometric accuracy, reduced material consumption and increased design flexibility. Geometrical accuracy is a critical issue in industries such as aerospace, automotive, medicine and consumer goods, hence the importance of the following question: can the dimensional optimisation of 3D FDM-manufactured parts be a solution for correct design? This paper presents a complex study of model parts printed from four common polymers used in fused deposition modelling (FDM) additive technology, namely ABS (acrylonitrile–butadiene–styrene), PLA (polylactic acid), HIPS (high-impact polystyrene) and PETG (polyethylene terephthalate glycol). The results of the methodology used highlight the dimensional changes that need to be made at the design stage, depending on the direction of printing and the type of geometric elements in the final part.