Rapid Prototyping Journal

Aroca, Rafael Vidal; Ventura, Carlos E.H.; De Mello, Igor; Pazelli, Tatiana F.P.A.T.

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-02-2016-0029

PurposeThis paper aims to present a monitoring system and the usage of a robotic arm to remove finished parts of a three-dimensional (3D) printer build plate, enabling 3D printers to continuously build a sequence of parts.Design/methodology/approachThe system relies on a 2-degree of freedom planar manipulator. The moment to remove printed parts from the printer build plate can be determined based on direct communication with the 3D printer control software or using information from a computer vision system that applies background subtraction and Speeded up Robust Features methods.FindingsThe proposed system automatically detects the end of standard 3D print jobs and controls the robotic arm to remove the part.Research limitations/implicationsLighting variation can deteriorate the response of the computer vision system, which can be minimized using a controlled illumination environment. In addition, the printer build plate edges must be free so the parts can slip off the printer build plate when the robot pushes them out.Practical implicationsThe system enables a more practical and automatized usage of 3D printers, reducing the need of human operators.Social implicationsThe proposed system can reduce work hours of laboratory personnel, as there is no need to remove the printed parts manually before another job starts.Originality/valueComputer vision system monitors the printing process and the automation system that enables continuous sequential 3D printing of parts. A prototype is described, which can be easily replicated with low cost parts.

Cheng, Lin; Zhang, Pu; Biyikli, Emre; Bai, Jiaxi; Robbins, Joshua; To, Albert

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-04-2016-0069

PurposeThe purpose of the paper is to propose a homogenization-based topology optimization method to optimize the design of variable-density cellular structure, in order to achieve lightweight design and overcome some of the manufacturability issues in additive manufacturing.Design/methodology/approachFirst, homogenization is performed to capture the effective mechanical properties of cellular structures through the scaling law as a function their relative density. Second, the scaling law is used directly in the topology optimization algorithm to compute the optimal density distribution for the part being optimized. Third, a new technique is presented to reconstruct the computer-aided design (CAD) model of the optimal variable-density cellular structure. The proposed method is validated by comparing the results obtained through homogenized model, full-scale simulation and experimentally testing the optimized parts after being additive manufactured.FindingsThe test examples demonstrate that the homogenization-based method is efficient, accurate and is able to produce manufacturable designs.Originality/valueThe optimized designs in our examples also show significant increase in stiffness and strength when compared to the original designs with identical overall weight.

van Eijnatten, Maureen; Berger, Ferco Henricus; de Graaf, Pim; Koivisto, Juha; Forouzanfar, Tymour; Wolff, Jan

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-07-2015-0092

PurposeAdditive manufactured (AM) skull models are increasingly used to plan complex surgical cases and design custom implants. The accuracy of such constructs depends on the standard tessellation language (STL) model, which is commonly obtained from computed tomography (CT) data. The aims of this study were to assess the image quality and the accuracy of STL models acquired using different CT scanners and acquisition parameters.Design/methodology/approachImages of three dry human skulls were acquired using two multi-detector row computed tomography (MDCT) scanners, a dual energy computed tomography (DECT) scanner and one cone beam computed tomography (CBCT) scanner. Different scanning protocols were used on each scanner. All images were ranked according to their image quality and converted into STL models. The STL models were compared to gold standard models.FindingsImage quality differed between the MDCT, DECT and CBCT scanners. Images acquired using low-dose MDCT protocols were preferred over images acquired using routine protocols. All CT-based STL models demonstrated non-uniform geometrical deviations of up to +0.9 mm. The largest deviations were observed in CBCT-derived STL models.Practical implicationsWhile patient-specific AM constructs can be fabricated with great accuracy using AM technologies, their design is more challenging because it is dictated by the correctness of the STL model. Inaccurate STL models can lead to ill-fitting implants that can cause complications after surgery.Originality/valueThis paper suggests that CT imaging technologies and their acquisition parameters affect the accuracy of medical AM constructs.

Armillotta, Antonio; Bianchi, Stefano; Cavallaro, Marco; Minnella, Stefania

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-02-2016-0021

PurposeThis paper aims to provide an experimental evaluation of geometric errors on the edges of parts manufactured by the fused deposition modeling (FDM) process.Design/methodology/approachAn 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.FindingsThe 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.Research limitations/implicationsThe experimental results refer to fixed process settings (material, FDM machine, layer thickness, build parameters, scan strategies).Originality/valueThe 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.

Ye, Hang; Venketeswaran, Abhishek; Das, Sonjoy; Zhou, Chi

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-06-2016-0091

PurposeOne of the major concerns of the constrained-surface stereolithography (SLA) process is that the built-up part may break because of the force resulting from the pulling-up process. This resultant force may become significant if the interface mechanism between the two contact surfaces (i.e. newly cured layer and the bottom of the resin vat) produces a strong bonding between them. The purpose of this paper is to characterize the separation process between the cured part and the resin vat by adopting an appropriate and simple mechanics-based model that can be used to probe the pulling-up process.Design/methodology/approachIn this paper, the time-histories of the pulling-up forces are measured using FlexiForce® force sensors. The experimental data are analyzed and used to estimate the constitutive parameters of the separation mechanism. Here, the separation mechanism is modeled based on the concept of cohesive zone model (CZM) that is well-studied in the field of fracture mechanics. By using the experimentally measured pulling-up force, this paper proposes a very efficient inverse technique to estimate the constitutive parameters for the CZM. The constitutive laws for the CZM facilitate in relating the separation force at the interface between the cured part and the resin vat in terms of the pulling-up velocity. Unlike work proposed earlier, computationally expensive full-scale finite element runs are not essential in the current work while estimating the required parameters of the constitutive laws. Instead, mechanics-based computationally efficient surrogate model is proposed to readily estimate these constitutive parameters.FindingsTwo constitutive laws are compared on the basis of their predictions of the separation force profile. Excellent match is obtained between the measured and the predicted separation force profiles.Originality/valueThis paper selects a suitable mechanics-based model that can characterize the separation process and proposes a computationally efficient scheme to estimate the required constitutive parameters. The proposed scheme can be used to reliably predict the separation force for the constrained-surface SLA process, leading to improved productivity and reliability of the SLA processes in fabricating the built-up parts.

Gheisari, Reza; Bártolo, Paulo; Goddard, Nicholas; Domingos, Marco Andre das Neves

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-10-2015-0152

PurposeThe use of microstereolithography (μSL) parts as micro-injection molding (μIM) tools greatly reduces the time and cost to product and offers unique solutions for complex design issues. However, they present challenges to designers because of their strength, thermal characteristics and shorter lifetimes as compared to other mold materials. The purpose of this study is to use SL to build rapid injection mold tools directly combining microfeatures for short-run production.Design/methodology/approachIn total, three tool inserts were produced. Two different μSL mold inserts were produced and evaluated in terms of different build approaches of micro features. One of the inserts includes micro features built horizontally, while the other one collaborates features built vertically, both having same geometrical dimensions. To evaluate the replication capability of prototype tools, two different thicknesses were set for micro features, that is, 30 and 120 μm. The mold inserts were assembled on a metallic mold frame and tested with polypropylene (PP).FindingsIt was observed that using inappropriate resin to fabricate the mold inserts can lead to inaccurate geometrical dimensions of the tool. Therefore, the material with high glass transition temperature (Tg) and low thermal conductivity is preferred. Also, the results of this research work showed that the processed material and technology play an important role both on part quality and tool life. After investigating the tool failure mechanisms during the injection, it was observed that tool failure occurred mainly because of excessive flexural stresses and ejection forces during the cavity filling and part ejection phases, respectively.Originality/valueThe paper describes the capability of μSL mold inserts for the production of small batches of micro-cantilevers which are used in MEMS relays.

Hassanin, Hany; Essa, Khamis; Qiu, Chunlei; Abdelhafeez, Ali M.; Adkins, Nicholas J.E.; Attallah, Moataz M.

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-02-2016-0019

PurposeThe purpose of this study is to develop a manufacturing technology using hybrid selective laser melting/hot isostatic pressing (SLM/HIP) process to produce full density net-shape components more rapidly and at lower cost than processing by SLM alone.Design/methodology/approachTi-6Al-4V powder was encapsulated in situ by the production of as-SLMed shell prior to the HIP process. After HIPping, the SLM shell is an integral part of the final component. Finite element (FE) modelling based on pure plasticity theory of porous metal coupled with an iterative procedure has been adopted to simulate HIPping of the encapsulated Ti-6Al-4V powder and SLMed shell. Two demonstrator parts have been modelled, designed, produced and experimentally validated. Geometrical analysis and microstructural characterisation have been carried out to demonstrate the efficiency of the process.FindingsThe FE model is in agreement with the measured data obtained and confirms that the design of the shell affects the resulting deformed parts. In addition, the scanning electron microscope (SEM) and Electron backscatter diffraction EBSD (EBSD) of the interior and exterior parts reveal a considerably different grain structure and crystallographic orientation with a good bonding between the SLMed shell and HIPped powder.Originality/valueAn approach to improve SLM productivity by combining it with HIP is developed to further innovate the advanced manufacturing field. The possibility of the hybrid SLS/HIP supported by FEA simulation as a net shape manufacturing process for fabrication of high performance parts has been demonstrated.

Khaliq, Muhammad Hussam; Gomes, Rui; Fernandes, Célio; Nóbrega, João; Carneiro, Olga Sousa; Ferrás, Luis Lima

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-02-2016-0027

PurposeThis work aims to provide additional insights regarding the practicability of using conventional materials in the fused filament fabrication (FFF) process.Design/methodology/approachTwo different acrylonitryle butadiene styrene (ABS) grades are studied and compared, aiming to check to what extent the regular ABS developed for conventional polymer processing, with a different rheology than the one provided for the FFF process, can also be used in this process (FFF).FindingsThe rheological results show that a general-purpose ABS (ABS-GP) melt is much more viscous and elastic than ABS-FFF. It is clear that using ABS-GP as feedstock material in the FFF process results in poor coalescence and adhesion between the extruded filaments, which has a detrimental effect on the mechanical properties of the printed specimens. Despite its lower performance, ABS-GP can be a good choice if the objective is to produce an aesthetical prototype. If the objective is to produce a functional prototype or a final part, its mechanical performance requirements will dictate the choice.Originality/valueThis work provides insightful information regarding the use of high viscosity materials on the 3D printing process.

Mohamed, Omar Ahmed; Masood, Syed Hasan; Bhowmik, Jahar Lal

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-10-2015-0137

PurposeFused deposition modeling (FDM) has become an increasingly important process among the available additive manufacturing technologies in various industries. Although there are many advantages of FDM process, a downside of its industrial application is the attainable dimensional accuracy with tight tolerance without compromising the mechanical performance. This paper aims to study the effects of six FDM operating parameters on two conflicting responses, namely, dynamic stiffness and dimensional stability of FDM produced PC-ABS parts. This study also aims to determine the optimal process settings using graphical optimization that satisfy the dynamic mechanical properties without compromising the dimensional accuracy.Design/methodology/approachThe regression models based upon IV-optimal response surface methodology are developed to study the variation of dimensional accuracy and dynamic mechanical properties with changes in process parameter settings. Statistical analysis was conducted to establish the relationships between process variables and dimensional accuracy and dynamic stiffness. Analysis of variance is used to define the level of significance of the FDM operating parameters. Scanning electron microscope and Leica MZ6 optical microscope are used to examine and characterize the morphology of the structures for some specimens.FindingsExperimental results highlight the individual and interaction effects of processing conditions on the dynamic stiffness and part accuracy. The results showed that layer thickness (slice height), raster-to-raster air gap and number of outlines have the largest effect on the dynamic stiffness and dimensional accuracy. The results also showed an interesting phenomenon of the effect of number of contours and the influence of other process parameters. The optimal process conditions for highest mechanical performance and part accuracy are obtained.Originality/valueThe effect of FDM processing parameters on the properties under dynamic and cyclic loading conditions has not been studied in the previous published work. Furthermore, simultaneous optimization of dynamic mechanical properties without compromising the dimensional accuracy has also been investigated. On the basis of experimental findings, it is possible to provide practical suggestions to set the optimal FDM process parameters in relation to dynamic mechanical performance, as well as the dimensional accuracy.

Yap, Chor Yen; Tan, Hongyi Kenneth; Du, Zhenglin; Chua, Chee Kai; Dong, Zhili

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-01-2016-0006

PurposeSelective laser melting (SLM) is an additive manufacturing technology that is gaining industrial and research interest as it can directly fabricate near full density metallic components. The paper aims to identify suitable process parameters for SLM of processing of pure nickel powder and to study the microstructure of such products. The study also aims to characterize the microhardness and tensile properties of pure nickel produced by SLM.Design/methodology/approachA 24 factorial design experiment was carried out to identify the most significant factors on the resultant porosity of nickel parts. A subsequent experiment was carried out with a laser power of 350 W. The scanning speeds and hatch spacings were varied.FindingsScanning speed and hatch spacing have significant effects on the porosity of SLM components. A high relative density of 98.9 per cent was achieved, and microhardness of 140 to 160 Hv was obtained from these samples. A tensile strength 452 MPa was obtained.Research limitations/implicationsAs the energy input levels were made in steps of 20 J/mm3 for the optimization study, the true optimal combination of parameters may have been missed. Therefore, researchers are encouraged to test the parameters with smaller variations in energy levels.Practical implicationsThe paper provides a set of optimized parameters for the SLM of pure nickel. This study enables the three-dimensional (3D) printing of objects with nickel, which has applications in chemical catalyses and in microelectromechanical systems with its magnetostrictive properties.Originality valueThis research is the first in direct processing of pure nickel using SLM, with the identification of suitable process parameters. The study also provides an understanding of the porosity, microhardness, strength and microstructure of SLM produced nickel parts. This work paves the way for standardization of 3D printed nickel components and enables the applications of pure nickel via SLM.

Chen, Changjun; Li, Yang; Zhang, Min; Wang, Xiaonan; Zhang, Chao; Jing, Hemin

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-05-2014-0068

PurposeAdditive manufacturing (AM), a method used in the nuclear, space and racing industries, allows the creation of customized titanium alloy scaffolds with highly defined external shape and internal structure using rapid prototyping as supporting external structures within which bone tissue can grow. AM allows porous tantalum parts with mechanical properties close to that of bone tissue to be obtained.Design/methodology/approachIn this paper, porous tantalum structures with different scan distance were fabricated by AM using laser multi-layer micro-cladding.FindingsPorous tantalum samples were tested for resistance to compressive force and used scanning electron microscope to reveal the morphology of before and after compressive tests. Their structure and mechanical properties of these porous Ta structures with porosity in the range of 35.48 to 50 per cent were investigated. The porous tantalum structures have comparable compressive strength 56 ∼ 480 MPa, and elastic modulus 2.8 ∼ 9.0GPa, which is very close to those of human spongy bone and compact bone.Research limitations/implicationsThis paper does not demonstrate the implant results.Practical implicationsIt can be used as implant material for the repair bone.Social implicationsIt can be used for fabrication of other porous materials.Originality/valueThis paper system researched the scan distance on how to influence the mechanical properties of fabricated porous tantalum structures.

Centeno, Gabriel; Morales-Palma, Domingo; Gonzalez-Perez-Somarriba, Borja; Bagudanch, Isabel; Egea-Guerrero, Juan José; Gonzalez-Perez, Luis Miguel; García-Romeu, María Luisa; Vallellano, Carpóforo

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-02-2016-0031

PurposeThis paper aims to propose a functional methodology to produce cranial prostheses in polymeric sheet. Within the scope of rapid prototyping technologies, the single-point incremental forming (SPIF) process is used to demonstrate its capabilities to perform customized medical parts.Design/methodology/approachThe methodology starts processing a patient’s computerized axial tomography (CAT) and follows with a computer-aided design and manufacture (CAD/CAM) procedure, which finally permits the successful manufacturing of a customized prosthesis for a specific cranial area.FindingsThe formability of a series of polymeric sheets is determined and the most restrictive material among them is selected for the fabrication of a specific partial cranial prosthesis following the required geometry. The final strain state at the outer surface of the prosthesis is analysed, showing the high potential of SPIF in manufacturing individualized cranial prostheses from polymeric sheet.Originality/valueThis paper proposes a complete methodology to design and manufacture polymer customized cranial prostheses from patients’ CATs using the novel SPIF technology. This is an application of a new class of materials to the manufacturing of medical prostheses by SPIF, which to this purpose has been mainly making use of metallic materials so far. Despite the use of polymers to this application is still to be validated from a medical point of view, transparent prostheses can already be of great interest in medical or engineering schools for teaching and research purposes.

Adhikary, N.; Gurumoorthy, B.

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-06-2015-0064

PurposeThis paper aims to propose an automatic and direct method to manipulate global parameters of the object for prototyping and simulation, given an STL mesh model of a thin-walled object. Proposed method is useful in rapid prototyping, where changing the global parameters such as thickness, scaling local features or draft of walls of an STL mesh is often required. Presently, user needs to iterate over the cycle of modification of the computer-aided design (CAD) model and tessellating it to change the global parameters. The proposed algorithm eliminates the need for CAD model while manipulating those global properties, as it works directly with the mesh model.Design/methodology/approachProposed algorithm automatically identifies walls and its thickness, and then, it extracts mid-surface from each wall. Global parameters are then modified by using these mid-surfaces.FindingsMesh directly modified and the mesh obtained by tessellating modified CAD model has same global properties; proposed method can also allow multiple parameters to be modified at the same time.Research limitations/implicationsInput STL model is assumed to be error-free, where models containing errors like self-intersection will lead to incorrect mid-surfaces. Present algorithm assumes that the mid-surface represent of the input STL model is a manifold surface.Originality/valueA novel algorithm of directly manipulating global parameters of a thin-walled object in its STL mesh model is proposed. The paper also presents a novel method of extracting mid-surface representation from a thin-wall STL mesh.

Santana, Leonardo; Ahrens, Carlos Henrique; da Costa Sabino Netto, Aurélio; Bonin, Cassiano

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-05-2016-0078

PurposeThe purpose of this study is to analyze the factors affecting the deposition of parts manufactured in poly(lactic acid) with variations in print speed and extrusion temperature. Specimens were analyzed through optical microscopy, mass measurements and flexural tests. The extruder-head evaluation consisted of monitoring the feedstock material displacement on entering the system during deposition under different processing conditions.Design/methodology/approachTo analyze the factors affecting the deposition, parts were manufactured in poly(lactic acid) with variations in print speed and extrusion temperature. Specimens were analyzed through optical microscopy, mass measurements and flexural tests. The extruder-head evaluation consisted of monitoring the feedstock material displacement on entering the system during deposition under different processing conditions.FindingsThe results showed low repeatability in the manufacturing of parts, as significant variations in the evaluated responses were found for specimens built under the same process parameters. The main cause for this effect was deposition failure, owing to filament slippage in the extruder head hobbed pulley.Practical implicationsThe results found should alert users to the fact that performance tests need to be carried out on every subcomponent of the equipment before conducting experiments on printing parameters. The components of the equipment can influence the final quality of the parts obtained as much as the building parameters and this influence can be significant enough to overlap with that of the process parameters.Originality/valueThe effect of slippage on the deposition quality was quantified and the command loss in the machine control board was identified.

Cao, Shiqing; Yu, Dandan; Xue, Weilan; Zeng, Zuoxiang; Zhu, Wanyu

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-12-2015-0197

PurposeThe purpose of this paper is to prepare a new modified polybutylene terephalate (MPBT) for fused deposition modeling (FDM) to increase the variety of materials compatible with printing. And the printing materials can be used to print components with a complex structure and functional mechanical parts.Design/methodology/approachThe MPBT, poly(butylene terephalate-co-isophthalate-co-sebacate) (PBTIS), was prepared for FDM by direct esterification and subsequent polycondensation using terephthalic acid (PTA), isophthalic acid (PIA), sebacic acid (SA) and 1,4-butanediol (BDO). The effects of the content of PIA (20-40 mol%) on the mechanical properties of PBTIS were investigated when the mole per cent of SA (αSA) is zero. The effects of αSA (0-7mol%) on the thermal, rheological and mechanical properties of PBTIS were investigated at nPTA/nPIA = 7/3. A desktop wire drawing and extruding machine was used to fabricate the filaments, whose printability and anisotropy were tested by three-dimensional (3D) printing experiments.FindingsA candidate content of PIA introducing into PBT was obtained to be about 30 per cent, and the Izod notched impact strength of PBTIS increased with the increase of αSA. The results showed that the PBTIS (nPTA/nPIA = 7/3, αSA = 3-5mol%) is suitable for FDM.Originality/valueNew printing materials with good Izod notched impact strength were obtained by introducing PIA and SA (nPTA/nPIA = 7/3, αSA = 3-5 mol%) into PBT and their anisotropy are better than that of ABS.

Cantrell, Jason T.; Rohde, Sean; Damiani, David; Gurnani, Rishi; DiSandro, Luke; Anton, Josh; Young, Andie; Jerez, Alex; Steinbach, Douglas; Kroese, Calvin; Ifju, Peter G.

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-03-2016-0042

PurposeThis paper aims to present the methodology and results of the experimental characterization of three-dimensional (3D) printed acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) parts utilizing digital image correlation (DIC).Design/methodology/approachTensile and shear characterizations of ABS and PC 3D-printed parts were performed to determine the extent of anisotropy present in 3D-printed materials. Specimens were printed with varying raster ([+45/−45], [+30/−60], [+15/−75] and [0/90]) and build orientations (flat, on-edge and up-right) to determine the directional properties of the materials. Tensile and Iosipescu shear specimens were printed and loaded in a universal testing machine utilizing two-dimensional (2D) DIC to measure strain. The Poisson’s ratio, Young’s modulus, offset yield strength, tensile strength at yield, elongation at break, tensile stress at break and strain energy density were gathered for each tensile orientation combination. Shear modulus, offset yield strength and shear strength at yield values were collected for each shear combination.FindingsResults indicated that raster and build orientations had negligible effects on the Young’s modulus or Poisson’s ratio in ABS tensile specimens. Shear modulus and shear offset yield strength varied by up to 33 per cent in ABS specimens, signifying that tensile properties are not indicative of shear properties. Raster orientation in the flat build samples reveals anisotropic behavior in PC specimens as the moduli and strengths varied by up to 20 per cent. Similar variations were observed in shear for PC. Changing the build orientation of PC specimens appeared to reveal a similar magnitude of variation in material properties.Originality/valueThis article tests tensile and shear specimens utilizing DIC, which has not been employed previously with 3D-printed specimens. The extensive shear testing conducted in this paper has not been previously attempted, and the results indicate the need for shear testing to understand the 3D-printed material behavior fully.

Vahabli, Ebrahim; Rahmati, Sadegh

2017 Rapid Prototyping Journal

doi: 10.1108/RPJ-06-2015-0075

PurposeTo improve the quality of the additive manufacturing (AM) products, it is necessary to estimate surface roughness distribution in advance. Although surface roughness estimation has been previously studied, factors leading to the creation of a rough surface and a comprehensive test for model validation have not been adequately investigated. Therefore, this paper aims to establish a robust model using empirical data based on optimized artificial neural networks (ANNs) to estimate the surface roughness distribution in fused deposition modelling parts. Accordingly, process parameters such as time, cost and quality should be optimized in the process planning stage.Design/methodology/approachProcess parameters were selected via a literature review of surface roughness estimation modelling by analytical and empirical methods, and then a specific test part was fabricated to provide a complete evaluation of the proposed model. The ANN structure was optimized by trial and error method and evolutionary algorithms. A novel methodology based on the combination of the intelligent algorithms including the ANN, linked to the particle swarm optimization (PSO) and imperialist competitive algorithm (ICA), was developed. The PSOICA algorithm was implemented to increase the capability of the ANN to perform much faster and converge more precisely to favorable results. The performances of the ANN models were compared to the most well-known analytical models at build angle intervals of equal size. The most effective process variable was found by sensitivity analysis. The validity of proposed model was studied comprehensively where different truncheon parts and medical case studies including molar tooth, skull, femur and a custom-made hip stem were built.FindingsThis paper presents several improvements in surface roughness distribution modelling including a more suitable method for process parameter selection according to the design criteria and improvements in the overall surface roughness of parts as compared to analytical methods. The optimized ANN based on the proposed advanced algorithm (PSOICA) represents precise estimation and faster convergence. The validity assessment confirms that the proposed methodology performs better in varied conditions and complex shapes.Originality/valueThis research fills an important gap in surface roughness distribution estimation modelling by using a test part designed for that purpose and optimized ANN models which uses purely empirical data. The novel PSOICA combination enhances the ability of the ANN to perform more accurately and quickly. The advantage in using actual surface roughness values is that all factors resulting in the creation of a rough surface are included, which is impossible if other methods are used.