This paper aims to assess the dimensional deviation of Fused Deposition Modeling (FDM) processed ABS and ULTRAT parts using a new geometrical model which can evaluate three types of dimensional deviation: along the z-axis, along external and internal dimensions, and through diameters. The methodology involves a step-by-step procedure wherein after establishing the experimental plan and manufacturing the specimens, the measurements taken are analyzed via Grey Relational Analysis (GRA) to find out the optimal combination of parameters leading to the minimum deviation in all dimensions of parts for both materials. Statistical techniques such as Analysis of Variance (ANOVA) and Signal to Noise (S/N) ratio were also used. Subsequently, a confirmation test was carried out to validate the results obtained. The findings of the ANOVA and the S/N ratio were in good concordance with those of GRA.

Despite the advantages that additive manufacturing (AM) processes present and the progressive number of activity sectors that they emerge in, their successful adoption is currently hampered by defects in surface finish as well as dimensional and geometrical precision. This results in reduction of their suitability for net shape manufacturing, thereby, requiring the evaluation of their performances. Considering this notion, this paper deals with in-plane deviation modeling of material shrinkage occurring in fused deposition modeling (FDM) process. To achieve this aim, two models were developed, each for circular and squared shapes. The objective was to first understand the deviation behavior, then compare it with actual data extracted from a test part to find out the rates with which the shrinkage would be compensated, and finally based on the obtained results, the CAD file would be modified. The experimental findings showed the effectiveness of the adopted methodology and the ability of developed models to compensate for the deviation.

Additive manufacturing (AM) has first emerged in 1987 with the invention of stereolithography. The AM is an important, rapidly emerging, manufacturing technology that takes the information from a computer-aided design (CAD) and builds parts in a layer-by-layer style. As this technology offers many advantages such as manufacturing of complex geometries, reducing manufacturing cost and energy consumption, it has transformed manufacturing from the mass production to the mass customization. Also, it has found wide applications in several fields although some drawbacks. This paper presents the state of the art of the different AM processes, the material processing issues, and the post-processing operations. A comparison between AM and conventional processes is presented as well. We finish by presenting some prospects of this technology such as hybrid manufacturing and 4D printing.