Analysis of Geometric Tolerances with Integration of Deviations Resulting from Additive Manufacturing (FDM): Case of Parallelism of a Plane Surface
 
More details
Hide details
1
Industrial Techniques and Services Laboratory, Sidi Mohamed ben Abdellah University ( Higher School of Technology), Morocco
 
 
Submission date: 2026-02-04
 
 
Final revision date: 2026-04-15
 
 
Acceptance date: 2026-05-11
 
 
Online publication date: 2026-05-26
 
 
Corresponding author
Ikram Kabbouri   

Industrial Techniques and Services Laboratory, Sidi Mohamed ben Abdellah University ( Higher School of Technology), Morocco
 
 
 
KEYWORDS
TOPICS
ABSTRACT
This study offers an updated overview of existing approaches used to model geometric deviations in additive manufacturing. It also proposes a new framework for representing part deviations by discretizing an ideal planar surface and accounting for both deterministic and stochastic sources of variation. Deterministic deviations are described through two main components: surface waviness and overall orientation. In contrast, stochastic deviations are introduced through automatically generated variations following a normal probability distribution. The second section of this work presents a numerical investigation of a prismatic component featuring a functional planar surface produced using the Fused Deposition Modeling (FDM) technique. As an initial step, a reference specimen is fabricated to verify essential parameters associated with the mathematical models used for the FDM process. The geometric deviation model relies on converting the nominal planar surface into a mesh of nodes, after which a deformed surface—representing the actual manufactured geometry is generated using the deviations computed by the proposed approach. Finally, a Monte Carlo analysis is performed to examine how these geometric variations influence the evaluation of surface parallelism tolerance. To support interpretation of the results, a correlation is established between the simulated deviations, the specified tolerance limits, and the resulting non conformity rate calculated for each tolerance range.
REFERENCES (24)
1.
SMITH J., NOVAK P., 2024, Geometric Accuracy of Cylindrical Parts in FDM Printing, Journal of Machine Engineering, 24/1, 45–58.
 
2.
NGUYEN C.V., DANG L.C., LE A.H., BUI D.T., 2023, A Study on the Influence of Printing Orientation in Metal Printing Using Material Extrusion Technology, Journal of Machine Engineering, 23/4, 89–100.
 
3.
A.EL-QEMARY et al., 2025, Anticipation and Correction of Additive Manufacturing Geometric Defects at the Design Stage, Journal of Machine Engineering, 25/2, 74–88.
 
4.
HOMRI L., DANTAN J.-Y., LEVASSEUR G., 2016, Comparison of Optimization Techniques in Tolerance Analysis Considering form Defects, Procedia CIRP, 43, 184–189.
 
5.
NGUYEN T.T., TRAN T.V., DAO S.H., 2024, Fabrication of Mold Using 3D Printing Technology and Surface Roughness Evaluation, Journal of Machine Engineering, 24/3, 106–118.
 
6.
SCHLEICH B, ANWER N., MATHIEU L, WARTZACK S., 2016, Status and Prospects of Skin Model Shapes for Geometric Variation Management, Procedia CIRP, 43, 154–159, https://doi.org/10.1016/j.proc....
 
7.
QIAO L., WU J., ZHU Z., CUI Y., 2016, Deviation Representation of Non-Ideal Cylindrical Surfaces, Procedia CIRP, 43, 17–22.
 
8.
MORIRE J., et al., 2010, Assembly Method Comparison Including Form Defect, Product Lifecycle Management, Wiley.
 
9.
HUANG W., CEGLAREK D., 2002, Mode-Based Decomposition of Part Form Error by DCT, CIRP Annals, 51/1, 21–26.
 
10.
SAMPER S., FORMOSA F. Form defects tolerancing by natural modes analysis, J. Comput. Inf. Sci. Eng., 7/1, 44–51, https://doi.org/10.1115/1.2424....
 
11.
CHAHBOUNI M., et al., 2014, Influence of Form Deviations on Tolerance Analyses, Int. J. Eng. Tech., 3, 343–349.
 
12.
CHAHBOUNI M., et al., 2020, New Approach to Form Deviations in Geometric Tolerance Analysis., Int. J. Eng. Tech.
 
13.
CHAHBOUNI M., 2016, Contribution to the Design of Mechanisms: Tolerance Analysis with the Influence of Form Defects, PhD Thesis, Morocco.
 
14.
ZHICHENG H., et al., 2018, Geometrical Deviation Identification and Prediction Method for Additive Manufacturin, Rapid Prototyping Journal.
 
15.
DANTAN J.-Y., et al., 2018, Geometrical Variations Management for Additive Manufactured Product, CIRP Annals – Manufacturing Technology, 66/1, 161–164.
 
16.
ZHU Z, ANWER N., MATHIEU L., 2016, Deviation Modelling and Shape Transformation in Design For AM, Procedia CIRP, 60, 211–216.
 
17.
WANG L., et al., 2023, Geometric Deviation Analysis in FDM Printing: Multiscale Prediction of Thermal-Induced Warping, Additive Manufacturing, 47, https://doi.org/10.1016/j.addm....
 
18.
CHEN Y., WU D., YANG Y., 2022, Hybrid Modeling of Geometric Errors in AM: A Thermo-Mechanical Approach, Journal of Manufacturing Processes, 77, https://doi.org/10.1016/j.jmap....
 
19.
ZHAO Q., et al., 2024, Data-Driven Prediction of Shape Deviations in Additive Manufacturing Using Machine Learning, Journal of Materials Processing Technology, 324, https://doi.org/10.1016/j.jmat....
 
20.
MARTINEZ D., et al., 2021, Modal Decomposition of Cylindrical Defects in Additive Manufacturing: A Comparative Study, Precision Engineering, 74, https://doi.org/10.1016/j.prec....
 
21.
GAO X., et al., 2023, Analytical Surface Deviation Modeling for FDM Process Optimization, International Journal of Advanced Manufacturing Technology, 128/5–6, https://doi.org/10.1007/s00170....
 
22.
LEE S., et al., 2020, Adaptive Geometric Modeling of Printing Orientation Effects in AM, Computer-Aided Design, 123, https://doi.org/10.1016/j.cad.....
 
23.
DUFLOU J.R., VERBERT J., SUTHERLAND J.W., DEWULF W., KELLENS K., 2013, An Investigation of the Anisotropy of Fuseddepositionmodeling (FDM), CIRP Annals, 62/1, 195–198, https://doi.org/10.1016/j.cirp....
 
24.
BOSCHETTO A., ET BOTTINI, L., 2015, Roughnessprediction in Fuseddepositionmodeling, Journal of Materials Processing Technology, 225, 291–298, https://doi.org/10.1016/j.jmat....
 
eISSN:2391-8071
ISSN:1895-7595
Journals System - logo
Scroll to top