Experimental Investigations for Development of Pattern for Dies Using FDM

Fused Deposition Modeling (FDM) is a relatively new prototyping technique in which parts can be produced rapidly and accurately. The component produced by FDM can be utilized for investment casting or it can be used for development of dies. The present work started with the identification of the bench mark/component. Prototypes were built with ABS plastic material and measurements were made on the co-ordinate measuring machine from which IT grades were calculated to check the dimensional accuracy of the components. The purpose of this study is to find whether the FDM process is capable of producing a pattern for manufacturing a die for hand tool with good dimensional accuracy. The study involves best settings of machine by varying the part orientations and studying the effect on the consumption of the model material, support material and the time taken for production. Measured mechanical properties like micro hardness indicated the suitability of the process. Final components produced are acceptable as per ISO standard UNI EN 20286-I (1995) and DIN16901.The results of study suggest FDM process lies within ± 6 sigma and value of cp, cpk is greater than 1 which conforms that FDM process is highly capable process for industrial applications.