Comparative Analysis of Additive Manufacturing Techniques for Snap-Fit Assembly: A Case Study

By allowing the production of complicated geometries with less tooling and material waste, Additive Manufacturing (AM) is transforming the fabrication of parts. The objective of this study is to compare the feasibility and performance of two AM techniques, Fused Deposition Modeling (FDM) and Stereolithography (SLA) to produce snap-fit plastic parts. The study specifically investigates how process parameters and prints orientation affect defect formation, dimensional accuracy, and structural suitability. The parts were assessed through qualitative defect analysis and quantitative dimensional measurements. Additionally, the effect of build orientation and support structure design was evaluated. A mathematical model was applied to estimate and validate printing time based on layer height. SLA parts demonstrated superior dimensional accuracy, with average deviations significantly lower than those observed in FDM prints. However, SLA was more prone to support-induced surface damage and brittleness. FDM produced structurally stronger but dimensionally less accurate parts, affected by brim residues and sagging. The validated print time model further confirmed the reliability of predictive manufacturing planning. Although AM, particularly SLA, seems encouraging for creating exact, low-volume snap-fit assemblies, both methods have their own difficulties. While FDM is preferable for fast prototyping of mechanically strong components, SLA is appropriate for applications needing critical details. The results underline AM's present constraints for mass production even if they show promise in generating tailored functional components.