Avaliação dos modos de falhas de peças fabricadas em uma impressora 3D usando diagrama de Ishikawa e FMEA

Abstract

Additive manufacturing has emerged as a promising technology for producing prototypes and final products, finding widespread application across various sectors. Among the available technologies, Fused Deposition Modeling (FDM) stands out for its accessibility, functionality, and speed in part development. Despite its advantages, the 3D printing process is prone to failures that can compromise the quality, dimensional accuracy, and performance of the produced parts. Consequently, it is important to identify the causes of these failures and propose measures to enhance process reliability and quality. This research was conducted at a small-scale 3D part manufacturing enterprise. The study aims to evaluate failure modes in the FDM 3D printing process using the Ishikawa Diagram and FMEA, while proposing actions to improve process reliability. Initially, the primary defects occurring during the printing process were identified. Next, the Ishikawa Diagram was applied to determine the possible causes of a failure. Subsequently, the Failure Mode and Effects Analysis (FMEA) methodology was used to assess the criticality of the failure mode and prioritize improvement actions. The results revealed that the failure regarding bed adhesion stemmed from two main causes: impurities and power instability, with the latter presenting the highest Risk Priority Number (RPN). It is concluded that the combined application of the Ishikawa Diagram and FMEA enabled the identification of the root causes of the observed defect and the prioritization of corrective and preventive actions to enhance process reliability and quality.