Comparative study of the geometric and dimensional quality of mechanical parts obtained by 3D printing with the FDM process for different materials

Abstract

This study investigates the dimensional accuracy and tolerance behavior of PLA, PETG, and ABS in FDM using the Raise3D Pro2 printer. Through a clearance fit test, a thread fit test, and a dimensional benchmark evaluation, the work provides a comprehensive comparison of how each material reproduces geometric features. The results consistently identified PLA as the most dimensionally accurate and process-reliable material. PETG showed inconsistent behavior, performing well on certain features while deviating significantly on others. ABS recorded the largest dimensional deviations and additionally presented a serious fabrication challenge. Overall, this study confirms that material selection in FDM directly governs both fabrication ease and dimensional fidelity, and that PLA is the most suitable choice when precision is a priority.