Two different approaches to design a sparse-build tool for fabrication by the fused deposition modeling (FDM) process are compared. One approach uses a 2D lattice structure and the other approach is inspired by topology optimization. Ultem 9085 is used as the material, and the amount of material used to build the tool is kept constant to ensure a fair comparison. A solid tool is also included in the comparison. The performance of the tool under uniform pressure is simulated using finite element analysis (FEA) and the accuracy of the FEA results is verified by comparing them with experimentally measured data for a similar tool. The build material, support material, build time, maximum displacement, and maximum von Mises stress are compared for the three build approaches, with an emphasis on the pros and cons of each sparsebuild tool with regards to performance under uniform pressure and fabrication by FDM.

Meeting Name

27th Annual International Solid Freeform Fabrication Symposium -- An Additive Manufacturing Conference (2016: Aug. 8-10, Austin, TX)


Mechanical and Aerospace Engineering

Research Center/Lab(s)

Intelligent Systems Center


This research is sponsored by the Industrial Consortium of the Center for Aerospace Manufacturing Technologies (CAMT) at Missouri University of Science and Technology.

Document Type

Article - Conference proceedings

Document Version

Final Version

File Type




Publication Date

10 Aug 2016

Included in

Manufacturing Commons