Effects of Electronic Layout and Beam Design on High-Speed Dynamic Characteristics of FFF 3D Printers

High-speed Fused Filament Fabrication (FFF) printers are prone to nozzle vibration caused by moving-part inertia, frame flexibility, and modal coupling during high-acceleration motion, which can reduce deposition-trajectory stability. This study evaluates the dynamic adaptability of electronics layout and X-axis beam configurations for a CoreXY FFF printer under complete-machine boundary conditions. A finite element model including the frame, XY motion mechanism, print head, heated bed, and electronics was established. Modal and Y-direction harmonic response analyses were performed by first comparing rear-mounted and bottom-mounted electronics layouts and then by comparing three beam designs. With the baseline beam, both layouts had a first natural frequency of 83 Hz, whereas the rear-mounted layout increased the second- to sixth-order frequencies by 6.8%, 24.2%, 32.0%, 29.2%, and 15.3%. Under the rear-mounted layout, the three beams showed similar first six modal frequencies, but the perforated beam produced the lowest nozzle peak, with a full-band Y-direction response of 0.402 mm, which was 16.1% and 20.4% lower than those of the baseline and hollow square beams, respectively. This beam also had a mass of 41.98 g, which was 45.1% lower than that of the baseline beam. Therefore, rear-mounted electronics combined with a perforated beam was preferred within the current simulation.