Evaluation of the Accuracy of a Fused Deposition Modeling Process in the Production of Low-Density ABS Lattice Structures

Fused Deposition Modeling (FDM) has emerged as one of the most widely adopted additive manufacturing (AM) technologies due to its broad material availability and low production costs, enabling the efficient production of complex geometries and customized components. Among the materials commonly used in AM, Acrylonitrile Butadiene Styrene (ABS) is particularly notable for its favorable mechanical properties, ease of processing, and versatility. While moderate-to-high-density lattice configurations have been extensively studied, low relative density lattice structures remain largely unexplored. This study investigates the feasibility of fabricating Cuboidal Body-Centered Cubic (BCC) lattice structures with relative densities of 5%, 10%, and 15% using FDM. The geometrical/dimensional accuracy of the printed samples is thoroughly assessed to quantify fabrication-induced deviations, focusing on strut geometry and overall lattice consistency. Results show that while smaller lattice configurations, particularly those with 5% relative density, exhibit significant geometrical inaccuracies due to printing limitations (e.g., strut waviness, material deposition inconsistencies, layer misalignment), larger configurations demonstrate improved dimensional and geometrical fidelity and structural integrity. A framework is proposed for assessing geometrical/dimensional fidelity, which can enhance the predictive modeling of these structures and optimize manufacturing processes. These findings clarify low relative density lattice manufacturability, guiding research on mechanical performance for lightweight aerospace applications.