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

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.