Fused Deposition Modeling (FDM) has become popular in additive manufacturing; nevertheless, achieving precision in small-scale features, such as micro-holes, is a considerable challenge. This study experimentally examines the impact of critical process factors on the dimensions and geometrical precision of a 0.8 mm diameter hole produced in PLA via an FDM printer. A square specimen (10 mm x 10 mm × 5 mm) including a centrally positioned hole was developed and fabricated using several build orientations (0°, 45°, and 90°), layer heights (0.05, 0.1, and 0.2 mm), printing speeds, and printing temperatures. An experimental strategy utilizing a one-factor-at-a-time methodology was employed, and a profile projector was utilized to assess dimensional deviation and roundness inaccuracy according to the minimum zone circle method. The findings demonstrate that build orientation substantially influences hole precision. Vertical printing (90°) enhances dimensional precision, whereas horizontal printing (0°) improves roundness. Increasing layer height results in increased dimensional inaccuracies while diminishing roundness deviation. Increased printing speeds somewhat increase dimensional inaccuracies while enhancing circularity. The printing temperature minimally impacts dimensional accuracy but enhances roundness at elevated levels. The results offer practical recommendations for optimizing FDM process parameters in the production of small-scale holes and enhance the functional performance of 3D-printed components with micro-features.

Keywords

3D Printing, Dimensional Accuracy, Roundness, Micro features, Micro Holes.