Process Parameter Optimization in Fused Deposition Modeling (FDM) Using Response Surface Methodology (RSM)

Abstract Fused Deposition Modeling (FDM) is a widely adopted additive manufacturing process to produce complex 3D structures and it is typically used in the fabrication of biodegradable materials e.g. PLA/PHA for biomedical applications. However, FDM as a fabrication process for such material needs to be optimized to enhance mechanical properties. In this study, dogbone and notched samples are printed with the FDM process to determine optimum values of printing parameters for superior mechanical properties. The effect of layer thickness, infill density, and print bed temperature on mechanical properties is investigated by applying response surface methodology (RSM). Optimum printing parameters are identified for tensile and impact strength and an empirical relation has been formulated with response surface methodology (RSM). Furthermore, the analysis of variance (ANOVA) was performed on the experimental results to determine the influence of the process parameters and their interactions. ANOVA results demonstrate that 44.7% infill density, 0.44 mm layer thickness, and 20C° printing temperatures are the optimum values of printing parameters owing to improved tensile and impact strength respectively. The experimental results were found in strong agreement with the predicted theoretical results.

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The Influence of Layer Thickness on Mechanical Properties of the 3D Printed ABS Polymer by Fused Deposition Modeling

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.706.63 ◽

2016 ◽

Vol 706 ◽

pp. 63-67 ◽

Cited By ~ 10

Author(s):

Pritish Shubham ◽

Arnab Sikidar ◽

Teg Chand

Keyword(s):

Mechanical Properties ◽

Tensile Strength ◽

Impact Strength ◽

Injection Molding ◽

Layer Thickness ◽

Fused Deposition Modeling ◽

Molding Method ◽

Fused Deposition ◽

Deposition Modeling ◽

3D Printed

3D Printed ABS polymer samples were investigated for understanding the effect of layer thickness on the various mechanical properties of the component. Standard samples with varying layer thickness were prepared by 3D printing machine which works on the principle of Fused Deposition modeling (FDM) method and compared with sample prepared by standard injection molding method. Results show that tensile strength (36 MPa), impact strength (103.6 J/m) and hardness (R107) were highest for the samples made by injection molding method. Furthermore, among 3D printed samples, properties were better with smaller layer thickness. With increase in layer thickness, there was negative effect on mechanical properties as tensile strength, impact strength and hardness decreased. Exception with hardness of 3D printed ABS samples was found; for largest layer thickness hardness further increased instead of decreasing.

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Synthesis and properties of modified PBT for FDM

Rapid Prototyping Journal ◽

10.1108/rpj-12-2015-0197 ◽

2017 ◽

Vol 23 (4) ◽

pp. 804-810 ◽

Cited By ~ 2

Author(s):

Shiqing Cao ◽

Dandan Yu ◽

Weilan Xue ◽

Zuoxiang Zeng ◽

Wanyu Zhu

Keyword(s):

Mechanical Properties ◽

Impact Strength ◽

Fused Deposition Modeling ◽

Complex Structure ◽

Three Dimensional ◽

Sebacic Acid ◽

Wire Drawing ◽

Content Type ◽

Fused Deposition ◽

Deposition Modeling

Purpose The purpose of this paper is to prepare a new modified polybutylene terephalate (MPBT) for fused deposition modeling (FDM) to increase the variety of materials compatible with printing. And the printing materials can be used to print components with a complex structure and functional mechanical parts. Design/methodology/approach The MPBT, poly(butylene terephalate-co-isophthalate-co-sebacate) (PBTIS), was prepared for FDM by direct esterification and subsequent polycondensation using terephthalic acid (PTA), isophthalic acid (PIA), sebacic acid (SA) and 1,4-butanediol (BDO). The effects of the content of PIA (20-40 mol%) on the mechanical properties of PBTIS were investigated when the mole per cent of SA (αSA) is zero. The effects of αSA (0-7mol%) on the thermal, rheological and mechanical properties of PBTIS were investigated at nPTA/nPIA = 7/3. A desktop wire drawing and extruding machine was used to fabricate the filaments, whose printability and anisotropy were tested by three-dimensional (3D) printing experiments. Findings A candidate content of PIA introducing into PBT was obtained to be about 30 per cent, and the Izod notched impact strength of PBTIS increased with the increase of αSA. The results showed that the PBTIS (nPTA/nPIA = 7/3, αSA = 3-5mol%) is suitable for FDM. Originality/value New printing materials with good Izod notched impact strength were obtained by introducing PIA and SA (nPTA/nPIA = 7/3, αSA = 3-5 mol%) into PBT and their anisotropy are better than that of ABS.

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Effect of process parameters on flexural strength and surface roughness in fused deposition modeling of PC-ABS material

Journal of Micromanufacturing ◽

10.1177/25165984211031115 ◽

2021 ◽

pp. 251659842110311

Author(s):

Shrikrishna Pawar ◽

Dhananjay Dolas1

Keyword(s):

Surface Roughness ◽

Flexural Strength ◽

Response Surface ◽

Layer Thickness ◽

Process Parameters ◽

Surface Finish ◽

Fused Deposition Modeling ◽

Build Orientation ◽

Fused Deposition ◽

Deposition Modeling

Fused deposition modeling (FDM) is one of the most commonly used additive manufacturing (AM) technologies, which has found application in industries to meet the challenges of design modifications without significant cost increase and time delays. Process parameters largely affect the quality characteristics of AM parts, such as mechanical strength and surface finish. This article aims to optimize the parameters for enhancing flexural strength and surface finish of FDM parts. A total of 18 test specimens of polycarbonate (PC)-ABS (acrylonitrile–butadiene–styrene) material are printed to analyze the effect of process parameters, viz. layer thickness, build orientation, and infill density on flexural strength and surface finish. Empirical models relating process parameters with responses have been developed by using response surface regression and further analyzed by analysis of variance. Main effect plots and interaction plots are drawn to study the individual and combined effect of process parameters on output variables. Response surface methodology was employed to predict the results of flexural strength 48.2910 MPa and surface roughness 3.5826 µm with an optimal setting of parameters of 0.14-mm layer thickness and 100% infill density along with horizontal build orientation. Experimental results confirm infill density and build orientation as highly significant parameters for impacting flexural strength and surface roughness, respectively.

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Effect of layer thickness on irreversible thermal expansion and interlayer strength in fused deposition modeling

Rapid Prototyping Journal ◽

10.1108/rpj-05-2016-0077 ◽

2017 ◽

Vol 23 (5) ◽

pp. 943-953 ◽

Cited By ~ 25

Author(s):

Anthony A. D’Amico ◽

Analise Debaie ◽

Amy M. Peterson

Keyword(s):

Mechanical Properties ◽

Thermal Expansion ◽

Flexural Strength ◽

Layer Thickness ◽

Fused Deposition Modeling ◽

Thermal Strain ◽

Content Type ◽

Fused Deposition ◽

Deposition Modeling ◽

The Impact

Purpose The aim of this paper is to examine the impact of layer thickness on irreversible thermal expansion, residual stress and mechanical properties of additively manufactured parts. Design/methodology/approach Samples were printed at several layer thicknesses, and their irreversible thermal expansion, tensile strength and flexural strength were determined. Findings Irreversible thermal strain increases with decreasing layer thickness, up to 22 per cent strain. Tensile and flexural strengths exhibited a peak at a layer thickness of 200 μm although the maximum was not statistically significant at a 95 per cent confidence interval. Tensile strength was 54 to 97 per cent of reported values for injection molded acrylonitrile butadiene styrene (ABS) and 29 to 73 per cent of those reported for bulk ABS. Flexural strength was 18 to 41 per cent of reported flexural strength for bulk ABS. Practical implications The large irreversible thermal strain exhibited that corresponding residual stresses could lead to failure of additively manufactured parts over time. Additionally, the observed irreversible thermal strains could enable thermally responsive shape in additively manufactured parts. Variation in mechanical properties with layer thickness will also affect manufactured parts. Originality/value Tailorable irreversible thermal strain of this magnitude has not been previously reported for additively manufactured parts. This strain occurs in parts made with both high-end and consumer grade fused deposition modeling machines. Additionally, the impact of layer thickness on tensile and flexural properties of additively manufactured parts has received limited attention in the literature.

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Effect of Printing Parameters on the Thermal and Mechanical Properties of 3D-Printed PLA and PETG, Using Fused Deposition Modeling

Polymers ◽

10.3390/polym13111758 ◽

2021 ◽

Vol 13 (11) ◽

pp. 1758

Author(s):

Ming-Hsien Hsueh ◽

Chao-Jung Lai ◽

Shi-Hao Wang ◽

Yu-Shan Zeng ◽

Chia-Hsin Hsieh ◽

...

Keyword(s):

Mechanical Properties ◽

Thermal Deformation ◽

Fused Deposition Modeling ◽

Complex Geometry ◽

Thermal And Mechanical Properties ◽

Fused Deposition ◽

Internal Structures ◽

Deposition Modeling ◽

3D Printed ◽

Printing Parameters

Fused Deposition Modeling (FDM) can be used to manufacture any complex geometry and internal structures, and it has been widely applied in many industries, such as the biomedical, manufacturing, aerospace, automobile, industrial, and building industries. The purpose of this research is to characterize the polylactic acid (PLA) and polyethylene terephthalate glycol (PETG) materials of FDM under four loading conditions (tension, compression, bending, and thermal deformation), in order to obtain data regarding different printing temperatures and speeds. The results indicated that PLA and PETG materials exhibit an obvious tensile and compression asymmetry. It was observed that the mechanical properties (tension, compression, and bending) of PLA and PETG are increased at higher printing temperatures, and that the effect of speed on PLA and PETG shows different results. In addition, the mechanical properties of PLA are greater than those of PETG, but the thermal deformation is the opposite. The above results will be a great help for researchers who are working with polymers and FDM technology to achieve sustainability.

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Correlation between production parameters and mechanical properties of ABS plus p430 fused deposition material

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/09544062211027205 ◽

2021 ◽

pp. 095440622110272

Author(s):

M Corsi ◽

S Bagassi ◽

MC Moruzzi ◽

L Seccia

Keyword(s):

Mechanical Properties ◽

Layer Thickness ◽

Fused Deposition Modeling ◽

Testing Machine ◽

Experimental Studies ◽

Deep Understanding ◽

Layer By Layer ◽

Fused Deposition ◽

Production Parameters ◽

Printing Parameters

Fused Deposition Modeling (FDM), is one of the most popular and widely used Additive Manufacturing filament based technology employing materials such as Acrylonitrile Butadiene Styrene (ABS), Polycarbonate (PC), Thermoplastic Polyurethane (TPU) and Polylactic Acid (PLA). In this technique, the part is built up layer-by-layer, affecting, both the resolution along the z-axis, and the mechanical properties dependent on the mesostructure, controlled by a large amount of production parameters such as layer thickness, raster orientation, number of contour and air gap. When dealing with functional and structural printed parts, a deep understanding of these tunable building parameters and their influence on the mechanical properties is of the utmost importance and over the years many experimental studies have been carried to investigate this need. This study is intended to explore specimens realized through FDM technique with different combinations of printing parameters to analyse their effect on the mechanical properties of ABS Plus p430. To this aim, tensile and compression specimens, had been designed and tested. Sixteen different types of tensile specimen had been realized by varying four different parameters, namely, layer thickness, part interior style, infill orientation and number of contours. Whereas, the number of compression specimens had been limited to four considering the variation of two parameters: layer thickness and part interior style. Three samples for each specimen had been produced in ABS Plus p430 using a Stratasys Fortus 250mc FDM printer and tested with a universal testing machine through tension and compression tests to analyse the correlation between printing parameters and material properties. Test results had led to important conclusions on the consistency and homogeneity of the mechanical properties and on the variation of the material’s performances in accordance with the different combinations of production parameters.

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Optimization of the Impact Attenuation Capability of Three-Dimensional Printed Hip Protector Produced by Fused Deposition Modeling Using Response Surface Methodology

3D Printing and Additive Manufacturing ◽

10.1089/3dp.2021.0014 ◽

2021 ◽

Author(s):

Suleiman Abimbola Yahaya ◽

Zaidi Mohd Ripin ◽

Mohamad Ikhwan Zaini Ridzwan

Keyword(s):

Response Surface Methodology ◽

Response Surface ◽

Fused Deposition Modeling ◽

Three Dimensional ◽

Hip Protector ◽

Fused Deposition ◽

Impact Attenuation ◽

Deposition Modeling ◽

The Impact

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Effect of Printing Parameters on the Mechanical Properties of Parts Fabricated with Open-Source 3D Printers in PLA by Fused Deposition Modeling

Mechanics and Mechanical Engineering ◽

10.2478/mme-2018-0070 ◽

2020 ◽

Vol 22 (4) ◽

pp. 895-908

Author(s):

M. Ouhsti ◽

B. El Haddadi ◽

S. Belhouideg

Keyword(s):

Mechanical Properties ◽

Polylactic Acid ◽

Fused Deposition Modeling ◽

Acrylonitrile Butadiene Styrene ◽

Fused Deposition Modelling ◽

Fused Deposition ◽

3D Printers ◽

Deposition Modeling ◽

Printed Materials ◽

Printing Parameters

Abstract3D polymer-based printers have become easily accessible to the public. Usually, the technology used by these 3D printers is Fused Deposition Modelling (FDM). The majority of these 3D printers mainly use acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) to fabricate 3D objects. In order for the printed parts to be useful for specific applications, the mechanical properties of the printed parts must be known. The aim of this study is to determine the tensile strength and elastic modulus of printed materials in polylactic acid (PLA) according to three important printing parameters such as deposition angle, extruder temperature and printing speed. The central composite design (CCD) was used to reduce the number of tensile test experiments. The obtained results show that the mechanical properties of printed parts depend on printing parameters. Empirical models relating response and process parameters are developed. The analysis of variance (ANOVA) was used to test the validity of models relating response and printing parameters. The optimal printing parameters are determined for the desired mechanical properties.

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