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This paper aims to provide an experimental evaluation of geometric errors on the edges of parts manufactured by the fused deposition modeling (FDM) process.

An experimental plan was conducted by building parts in ABS thermoplastic resin on a commercially available machine with given combinations of the three geometric variables (inclination, included and incidence angle) defined in the first part of the paper. Edges on built parts were inspected on a two-dimensional non-contact profilometer to measure position and form errors.

The analysis of measurement results revealed that the edge-related variables have significant influences on the geometric errors. The interpretation of error variations with respect to the different angles confirmed the actual occurrence of the previously discussed error causes. As an additional result, quantitative predictions of the errors were provided as a function of angle values.

The experimental results refer to fixed process settings (material, FDM machine, layer thickness, build parameters, scan strategies).

The two-part paper is apparently the first to have studied the edges of additively manufactured parts with respect to geometric accuracy, a widely studied topic for surface features.

The purpose of this paper is to propose a method for simulating the profile of part edges as a result of the FDM process. Deviations from nominal edge shape are predicted as a function of the layer thickness and three characteristic angles depending on part geometry and build orientation.

Typical patterns of edge profiles were observed on sample FDM parts and interpreted as the effects of possible toolpath generation strategies. An algorithm was developed to generate edge profiles consistent with the patterns expected for any combination of input variables.

Experimental tests confirmed that the simulation procedure can correctly predict basic geometric properties of edge profiles such as frequency, amplitude and shape of periodic asperities.

The algorithm takes into account only a subset of the error causes recognized in previous studies. Additional causes could be integrated in the simulation to improve the estimation of geometric errors.

Edge simulation may help avoid process choices that result in aesthetic and functional defects on FDM parts.

Compared to the statistical estimation of geometric errors, graphical simulation allows a more detailed characterization of edge quality and a better diagnosis of error causes.