A challenge for enhancing the dimensional accuracy of a low-cost 3D printer by means of self-replicated parts

Owing to the lack of optimization, the dimensional accuracy of low-cost 3D printers is quite limited. In order to enhance the performances of a Prusa i3 3D printer, an optimization challenge was assigned to the students of the Specializing Master in Industrial Automation of the Politecnico di Torino. The enhancements were applied to four printers using new self-replicated parts that were produced by means of the same machines. The results of the challenge were validated by a benchmarking analysis. The benchmarking involved the fabrication of an innovative reference artifact using the modified printers. A coordinate measuring machine (CMM) was then used to inspect the dimensions of the replicas. Measurement results were used to compare the performances of the four optimized printers in terms of dimensional accuracy through ISO IT grades. The form errors of the geometrical features of the replicas were also evaluated according to the GD&T system.