Effect and Analysis of Overlap Rate on Top Surface Roughness of Printed Parts in Melt Deposition Molding Process

LI Junmei; HUANG Zifan; ZHANG Dehai; YANG Chunhui

doi:10.3969/j.issn.1674-6457.2025.11.022

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (11) : 229-241. DOI: 10.3969/j.issn.1674-6457.2025.11.022

Additive Manufacturing

Effect and Analysis of Overlap Rate on Top Surface Roughness of Printed Parts in Melt Deposition Molding Process

LI Junmei^1,2, HUANG Zifan^1,2, ZHANG Dehai^3,*, YANG Chunhui⁴

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Abstract

The work aims to reveal the formation mechanism of the top surface ripple effect in fused deposition modeling (FDM) printed parts and establish a theoretical model for predicting top surface roughness, so as to guide process parameter optimization and ultimately achieve precise control of top surface quality. Firstly, the generation mechanism of the periodic waviness effect on the top surface of printed parts was investigated, and a geometric model related to the relationship between overlap rate and top surface roughness was established. The accuracy of the top surface roughness model was then experimentally verified for different layer heights and overlap rates, and the sources of error were analyzed. Finally, based on the model, the intrinsic relationship between process parameters such as layer height, feed length, and printing rate and top surface roughness was elucidated. As the overlap rate increased from zero to the critical overlap rate, the top surface roughness gradually decreased. This was because the overlap area gradually filled the air gap area. Layer height not only directly affected top surface quality by changing the overlap rate but also caused a difference in the relative rate of change between the air gap area and the overlap area. This dual effect was the primary factor that led to the significant nonlinear characteristics of the effect of layer height on top surface roughness. The edge effect of extruded filaments is the root cause of top surface roughness, and the overlap rate is the key parameter affecting top surface roughness. This conclusion lays a theoretical foundation for optimizing the top surface roughness of printed parts.

Key words

top surface roughness model / edge effect of extruded filaments / overlap rate between adjacent extruded filaments / top surface ripple effect / top surface secondary ripples / critical overlap rate

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LI Junmei, HUANG Zifan, ZHANG Dehai, YANG Chunhui. Effect and Analysis of Overlap Rate on Top Surface Roughness of Printed Parts in Melt Deposition Molding Process[J]. Journal of Netshape Forming Engineering. 2025, 17(11): 229-241 https://doi.org/10.3969/j.issn.1674-6457.2025.11.022

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Funding

Henan Province Science and Technology Projects (182102210136); Key Scientific Research Projects of Henan Higher Education Institutions (25B460012); Zhengzhou Institute of Science and Technology