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When it comes to deciding which additive manufacturing (AM) system is best for you, there are so many important questions to consider. Which type of AM technology is the best for your particular use case? How fast can it build objects? Is it accurate and consistent? Is it easy to use? How much does it cost to own, operate, and maintain one AM system compared to others?
Like with most of life’s important questions, these answers are not easy to find. You can ask the manufacturer, but each one will tell you that its AM system is better, faster, and less expensive than the competitions’. You can read reviews online or ask around on Reddit, but you are putting a lot of trust into strangers (or maybe even paid shills). You could even buy it and try it for yourself if you’ve got the time, money, and you like to gamble.
Or you could just trust the experts…
For the past five years, Keypoint Intelligence has been testing AM systems from some of the biggest additive manufacturing companies on the planet. During that time, we’ve formulated a comprehensive testing program to determine how a given AM system will perform in each environment and how it stacks up against its competition. We evaluate everything from build speed and object accuracy to ease of use and total cost of ownership so consumers can make informed buying decisions and get the most out of their AM investment.
In this blog, we are going to focus on some of the tests that we use to measure the most important metric there is: accuracy. Of all the results that we collect during each test, object accuracy is the most important. Fast build speeds will not save you any time, low cost of ownership will not save you any money, and a simple user experience will not eliminate frustrations if you have to build the same object three times before it can be used.
Keypoint’s AM Object Accuracy Testing Explained
When we talk about “accuracy,” what we mean is the device’s ability to build objects to a targeted specificity. To test object accuracy, Keypoint Intelligence’s lab technicians built several American Society for Testing and Materials (ASTM)-compliant and proprietary test objects using the build materials provided by the manufacturer and different layer height settings (lowest, middle, and highest). Once the objects are built, our technicians clean and cure the object then measure the dimensions of each object to see if is built to the targets specified. All that test data is entered into a database, where we can compare the performance of one device versus others.
The results of each test help us understand the tolerances the device is capable of meeting when printing different objects, allowing us to assess how effective it will be for different use cases. Below, we will review some of the basic accuracy tests that we conduct on each object submitted to our lab.
| 25 mm cube built using the Nexa 3D XiP |
The 25 mm cube test object acts as a general benchmark for accuracy in our accuracy testing. To begin, technicians measure the X, Y, and Z axes using a digital caliper. The outside diameter and pin block test objects allow us to see how accurate the device is when building objects with radial characteristics, like holes, fittings, fixtures, and curved objects.
For the outside diameter test object, Keypoint’s technicians use a micrometer and digital caliper to measure each layer’s outside diameter (from top to bottom, each layer should measure 2.5, 5, 10, 15, 20, and 25 mm, respectively).
For the pin block test, lab technicians use pin gauges to measure the internal diameter of each hole. Technicians start by trying to insert the pin that measures the expected size of each hole (for example, when testing the 0.500 hole, technicians start with a 0.500 pin). Technicians continue to insert increasingly larger or smaller test pins (0.001 mm at a time) until they find the proper fit.
| Outside diameter and pinblock test objects printed by Formlabs Form3+ | |
The resolution slot helps us understand how proficient the device will be when building objects with fine details or objects with negative space between two characteristics. To measure the resolution slot results, our technicians use gage blocks to measure each slot, starting with the gage block that matches the expected measurement. Technicians continue inserting increasingly larger or smaller gage blocks until they find the right fit. Slots should measure 1, 2, 3, 4, 5, and 6 mm from left to right, respectively.
| Resolution Slot Test Object Built Using the Shining 3D Accufab-L4D |
Keypoint Intelligence Opinion
Take the guess work out of finding the AM technology that can help your business thrive. Keypoint Intelligence is the premier test lab for the AM industry, providing consumers with objective, unbiased competitive analysis so they can make smart, data-driven buying decisions.
Do you manufacture additive manufacturing systems? Click here to learn more about Keypoint Intelligence’s AM testing program. If you have any questions about the program, contact us for more info by clicking here.