Dimensional accuracy of additively manufactured structures for modular coil windings of stellarators

Highlights: • Dimensional accuracy of plastic additive manufacturing (AM) studied for fusion. • 0.1% accuracy obtained for FDM (Fused Deposition Modelling) AM fabrication. • AM of plastics near of adequate accuracy for winding structures for stellarators. • Reasonable cost for the studied parts. - Abstract: The paper studies the dimensional accuracy of additively manufactured (AM) coil winding structures for small experimental stellarators fabricated under industrial non-laboratory conditions. Insufficient accuracy is one of the main issues hindering the use of additive manufacturing (AM) for coil windings structures (coil casings and coil forms or frames) for stellarators. The dimensional accuracy of one complex modular coil frame and four planar coil casings is studied for different AM techniques and materials, in particular Selective Laser Sintering (SLS) in polyamide, Stereolithography (SLA) in resin, Fused Deposition Modelling (FDM) in ABS and PolyJet in resin. The measurements are performed by a Mitutoyo Coordinate Measuring Machine. The AM parts are hollow for subsequent internal casting with (fibre-reinforced) resin for strength and performance enhancement, method named 3Dformwork. The paper reports the features of the sample parts, the metrology methodology utilised, the performed measurements and the resulting dimensional deviations for each AM technique. Professional AM in FDM showed deviation between nominal dimensions and measurements of ±0.1% (one sigma, 68% of measurements) and PolyJet ±0.15%. Personal web-based AM in SLA exhibited deviation ±0.3% and SLS in polyamide ±0.4% (one sigma). The PolyJet part showed dimensional instability under harsh environment and would require immediate 3Dformwork. The FDM part presented the lower cost for the particular case study among the professional AM. Thus, high quality PolyJet and FDM additive manufacturing in plastics are at the verge of achieving the requirement of 0.1% minimum accuracy for stellarator coil windings. Therefore, AM may contribute to the fabrication of accurate winding structures for stellarators and other accurate components in fusion.