Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

This article reports on the investigation of the effects of process parameters and their interactions on as-built part quality and resource-efficiency of the fused filament fabrication 3D printing process. In particular, the influence of five process parameters: infill percentage, layer thickness, printing speed, printing temperature, and surface inclination angle on dimensional accuracy, surface roughness of the built part, energy consumption, and productivity of the process was examined using Taguchi orthogonal array (L50) design of experiment. The experimental results were analyzed using ANOVA and statistical analysis, and the parameters for optimal responses were identified. Regression models were developed to predict different process responses in terms of the five process parameters experimentally examined in this study. It was found that dimensional accuracy is negatively influenced by high values of layer thickness and printing speed, since thick layers of printed material tend to spread out and high printing speeds hinder accurate deposition of the printed material. In addition, the printing temperature, which regulates the viscosity of the used material, plays a significant role and helps to minimize the dimensional error caused by thick layers and high printing speeds, whereas the surface roughness depends very much on surface inclination angle and layer thickness, which together determine the influence of the staircase effect. Energy consumption and productivity are primarily affected by printing speed and layer thickness, due to their high correlation with build time.

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Preparation of Hydrophobic Surface on PLA and ABS by Fused Deposition Modeling

Polymers ◽

10.3390/polym12071539 ◽

2020 ◽

Vol 12 (7) ◽

pp. 1539 ◽

Cited By ~ 1

Author(s):

Huadong Yang ◽

Fengchao Ji ◽

Zhen Li ◽

Shuai Tao

Keyword(s):

Surface Roughness ◽

Layer Thickness ◽

Process Parameters ◽

Fused Deposition Modeling ◽

Hydrophobic Coatings ◽

Fused Deposition ◽

Filling Method ◽

Deposition Modeling ◽

Experiment Analysis ◽

Printing Speed

In the fields of agriculture, medical treatment, food, and packaging, polymers are required to have the characteristics of self-cleaning, anti-icing, and anti-corrosion. The traditional preparation method of hydrophobic coatings is costly and the process is complex, which has special requirements on the surface of the part. In this study, fused deposition modeling (FDM) 3D printing technology with design and processing flexibility was applied to the preparation of hydrophobic coatings on polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) parts, and the relationship between the printing process parameters and the surface roughness and wettability of the printed test parts was discussed. The experimental results show that the layer thickness and filling method have a significant effect on the surface roughness of the 3D-printed parts, while the printing speed has no effect on the surface roughness. The orthogonal experiment analysis method was used to perform the wettability experiment analysis, and the optimal preparation process parameters were found to be a layer thickness of 0.25 mm, the Grid filling method, and a printing speed of 150 mm/s.

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Effects of Process Parameters on Surface Roughness, Dimensional Accuracy and Printing Time in 3D Printing

Lecture Notes in Mechanical Engineering - Advances in Production and Industrial Engineering ◽

10.1007/978-981-15-5519-0_15 ◽

2020 ◽

pp. 187-197

Author(s):

Rajat Jain ◽

Shivansh Nauriyal ◽

Vishal Gupta ◽

Kanwaljit Singh Khas

Keyword(s):

Surface Roughness ◽

3D Printing ◽

Process Parameters ◽

Dimensional Accuracy ◽

Printing Time

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Pengaruh Setting Parameter pada Slicing Software terhadap Surface Roughness Objek 3D Printing menggunakan Metode Taguchi

Jurnal Rekayasa Mesin ◽

10.32497/jrm.v16i3.2519 ◽

2021 ◽

Vol 16 (3) ◽

pp. 319

Author(s):

Hasdiansah Hasdiansah ◽

Sugiyarto Sugiyarto

Keyword(s):

Surface Roughness ◽

3D Printing ◽

Layer Thickness ◽

Fused Deposition Modelling ◽

Fused Deposition ◽

Cooling Speed ◽

G Code ◽

Nozzle Temperature ◽

Printing Speed

Teknologi FDM (Fused Deposition Modelling) merupakan salah satu teknologi yang digunakan untuk membuat objek 3D. FDM sering disebut sebagai teknologi yang sudah mampu mengubah dunia manufaktur dewasa ini. Namun teknologi FDM memiliki kelemahan karena teknologi ini menggunakan proses building per layer membuat permukaan yang dihasilkan terlihat memiliki garis yang menunjukan batas antar layer sehingga mempengaruhi kekasaran pada permukaan produk cetak. Penelitian ini menggunakan filamen Super Tough PLA (ST.PLA). Tujuan penelitian ini adalah untuk mengetahui pengaruh parameter proses terhadap kekasaran permukaan objek cetak dan untuk mengetahui seting parameter proses yang menghasilkan kekasaran permukaan terbaik dari parameter proses yang digunakan. Penelitian ini menggunakan metode Taguchi dengan matriks ortogonal L25(56). Parameter proses yang akan dipilih dan dianalisis dalam penelitian ini adalah layer thickness, printing speed, nozzle temperature, orientation, flowrate, cooling speed dan respon yang diamati adalah kekasaran permukaan objek cetak. Untuk mengatasi permasalahan noise (gangguan) maka dicetak masing-masing tiga kali replikasi Selanjutnya parameter proses tersebut akan dianalisis menggunakan Analisis Varian (ANOVA). Berdasarkan data hasil pengukuran kekasaran permukaaan objek cetak, maka diperoleh parameter proses yang memberikan pengaruh paling besar terhadap kekasaran permukaan objek cetak dengan menggunakan filamen ST-PLA adalah layer thickness dengan nilai F hitung sebesar 129,96, flowrate dengan nilai F hitung sebesar 6 dan orientation dengan nilai F hitung sebesar 3,03. Seting parameter proses yang menghasilkan nilai kekasaran permukaan terbaik objek cetak adalah 0,10 mm yaitu pada eksperimen nomor lima (Exp. No. 5) dengan rata-rata 12,61 µm, dengan pengaturan layer thickness, 45 mm/s pada pengaturan printing speed, 210˚C pada nozzle temperature, 0˚ pada orientation, 110% pada pengaturan flowrate dan 40% pada pengaturan cooling speed. Seluruh parameter proses tersebut disetting pada slicing software ideamaker 3.6.1. dalam menghasilkan G-Code objek cetak.

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Experimental study of surface roughness, dimensional accuracy and time of fabrication of parts produced by fused deposition modelling

Rapid Prototyping Journal ◽

10.1108/rpj-12-2019-0315 ◽

2020 ◽

Vol 26 (9) ◽

pp. 1535-1554

Author(s):

Swapnil Vyavahare ◽

Shailendra Kumar ◽

Deepak Panghal

Keyword(s):

Experimental Study ◽

Surface Roughness ◽

Layer Thickness ◽

Process Parameters ◽

Dimensional Accuracy ◽

Fused Deposition Modelling ◽

Content Type ◽

Build Orientation ◽

Fused Deposition ◽

Significant Process

Purpose This paper aims to focus on an experimental study of surface roughness, dimensional accuracy and time of fabrication of parts produced by fused deposition modelling (FDM) technique of additive manufacturing. The fabricated parts of acrylonitrile butadiene styrene (ABS) material have pyramidal and conical features. Influence of five process parameters of FDM, namely, layer thickness, wall print speed, build orientation, wall thickness and extrusion temperature is studied on response characteristics. Furthermore, regression models for responses are developed and significant process parameters are optimized. Design/methodology/approach Comprehensive experimental study is performed using response surface methodology. Analysis of variance is used to investigate the influence of process parameters on surface roughness, dimensional accuracy and time of fabrication in both outer pyramidal and inner conical regions of part. Furthermore, a multi-response optimization using desirability function is performed to minimize surface roughness, improve dimensional accuracy and minimize time of fabrication of parts. Findings It is found that layer thickness and build orientation are significant process parameters for surface roughness of parts. Surface roughness increases with increase in layer thickness, while it decreases initially and then increases with increase in build orientation. Layer thickness, wall print speed and build orientation are significant process parameters for dimensional accuracy of FDM parts. For the time of fabrication, layer thickness and build orientation are found as significant process parameters. Based on the analysis, statistical non-linear quadratic models are developed to predict surface roughness, dimensional accuracy and time of fabrication. Optimization of process parameters is also performed using desirability function. Research limitations/implications The present study is restricted to the parts of ABS material with pyramidal and conical features only fabricated on FDM machine with delta configuration. Originality/value From the critical review of literature it is found that some researchers have made to study the influence of few process parameters on surface roughness, dimensional accuracy and time of fabrication of simple geometrical parts. Also, regression models and optimization of process parameters has been performed for simple parts. The present work is focussed on studying all these aspects in complicated geometrical parts with pyramidal and conical features.

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A novel technique for reducing lead-time and energy consumption in fabrication of Inconel-625 parts by laser-based metal deposition process

Rapid Prototyping Journal ◽

10.1108/rpj-07-2013-0070 ◽

2016 ◽

Vol 22 (2) ◽

pp. 269-280 ◽

Cited By ~ 8

Author(s):

A.R. Vinod ◽

C.K. Srinivasa ◽

R. Keshavamurthy ◽

P.V. Shashikumar

Keyword(s):

Surface Roughness ◽

Energy Consumption ◽

Process Parameters ◽

Lead Time ◽

Dimensional Accuracy ◽

Metal Deposition ◽

Inconel 625 ◽

Content Type ◽

Density Surface ◽

Time And Energy

Purpose This paper aims to focus on reducing lead-time and energy consumption for laser-based metal deposition of Inconel-625 superalloy and to investigate the effect of process parameters on microstructure, density, surface roughness, dimensional accuracy and microhardness. Design/methodology/approach Inconel material was deposited on steel substrate by varying process parameters such as laser power, laser scan speed and powder flow rate. The deposited parts were characterized for their density, surface roughness, dimensional accuracy and microhardness. Findings The study reveals that with increase in laser power, laser scan speed and powder flow rate, there was an increase in density, surface roughness values and microhardness of the deposits, while there was a decrease in dimensional accuracy, deposition time and energy consumption. Practical implications The results of this study can be useful in fabrication of Inconel components by laser-based metal deposition process, and the methodology can be expanded to other materials to reduce the lead-time and energy consumption effectively. Originality/value The present study gives an understanding of effect of process parameters on density, surface roughness, dimensional accuracy, microhardness, deposition time and energy consumption for laser-based metal deposition of Inconel-625.

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Pengaruh Geometri Infill terhadap Kekuatan Tarik Spesimen Uji Tarik ASTM D638 Type IV Menggunakan Filamen PLA+ Sugoi

Jurnal Rekayasa Mesin ◽

10.32497/jrm.v16i2.2343 ◽

2021 ◽

Vol 16 (2) ◽

pp. 140

Author(s):

Hasdiansah Hasdiansah ◽

Zaldy Sirwansyah Suzen

Keyword(s):

Surface Roughness ◽

3D Printing ◽

Layer Thickness ◽

Travel Speed ◽

Fused Deposition Modelling ◽

Fused Deposition ◽

Type Iv ◽

Bed Temperature ◽

Nozzle Temperature ◽

Printing Speed

Pengaturan parameter proses 3D Printing berteknologi Fused Deposition Modelling (FDM) sangat mempengaruhi kualitas produk cetak baik dalam hal akurasi dimensi, surface roughness, dan kekuatan tariknya. Dua material yang paling sering digunakan para praktisi 3D Printing adalah PLA dan ABS masih memerlukan pengaturan parameter proses pada slicing software untuk menghasilkan produk cetak paling kuat ditinjau dari kuat tariknya. Penelitian ini memvariasikan bentuk geometri infill yang tersedia pada Ultimaker Cura 4.8.0 dalam mencetak spesimen uji tarik ASTM D638 Type IV. Ada 13 (tiga belas) bentuk infill yang digunakan dengan infill density 100%. Ada 3 (tiga) variasi nozzle temperature yaitu 205°C, 215°C, dan 225°C. Parameter proses yang tetap seperti layer thickness 0,2 mm, printing speed 50 mm/s, travel speed 100 mm/s, dan bed temperature 60°C. Spesimen uji tarik dicetak masing-masing tiga buah pada 39 (tiga puluh sembilan) eksperimen dan rata-rata hasil uji tarik dihitung kemudian selanjutnya dianalisis. Nilai kekuatan tarik tertinggi diperoleh pada pengaturan nozzle temperature 205°C dengan bentuk infill concentric atau terdapat pada eksperimen nomor 9 dengan nilai 32,40 MPa. Sedangkan nilai kekuatan tarik diperoleh pada pengaturan nozzle temperature 225°C dan dengan bentuk infill cross atau pada eksperimen nomor 37 dengan nilai 19,10 MPa. Sehingga dapat disimpulkan bahwa bentuk geometri infill pada proses 3D Printing FDM sangat mempengaruhi kekuatan tarik produk cetak.

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Optimization of 3D printing process parameters to minimize surface roughness with hybrid artificial neural network model and particle swarm algorithm

Progress in Additive Manufacturing ◽

10.1007/s40964-021-00166-6 ◽

2021 ◽

Author(s):

Mohammad Shirmohammadi ◽

Saeid Jafarzadeh Goushchi ◽

Peyman Mashhadi Keshtiban

Keyword(s):

Neural Network ◽

Surface Roughness ◽

Artificial Neural Network ◽

3D Printing ◽

Network Model ◽

Process Parameters ◽

Neural Network Model ◽

Artificial Neural Network Model ◽

Particle Swarm Algorithm ◽

Hybrid Artificial Neural Network

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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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A water droplet-cleaning of a dusty hydrophobic surface: influence of dust layer thickness on droplet dynamics

Scientific Reports ◽

10.1038/s41598-020-71743-y ◽

2020 ◽

Vol 10 (1) ◽

Author(s):

Ghassan Hassan ◽

Bekir S. Yilbas ◽

Saeed Bahatab ◽

Abdullah Al-Sharafi ◽

Hussain Al-Qahtani

Keyword(s):

Layer Thickness ◽

Inclination Angle ◽

Water Droplet ◽

High Speed ◽

Small Volume ◽

Transition Period ◽

Imaging System ◽

Hydrophobic Surface ◽

Dust Layer ◽

Surface Inclination

Abstract Water droplet cleaning of a dusty hydrophobic surface is examined. Environmental dust are used in the experiments and cloaking velocity of a dust layer by a droplet fluid is measured and hemi-wicking conditions for the dust layer are analyzed adopting the pores media wick structure approach. A droplet motion on dusty and inclined hydrophobic surface is analyzed using a high speed digital imaging system. Influences of dust layer thickness, droplet volume, and surface inclination angle on the mechanisms of dust removal by a rolling droplet are evaluated. The findings revealed that dust cloaking velocity decreases exponentially with time. The droplet fluid can cloak the dust layer during its transition on the dusty surface. The transition period of droplet wetted length on the dusty surface remains longer than the cloaking time of the dust layer by the droplet fluid. Translational velocity of rolling droplet is affected by the dust layer thickness, which becomes apparent for small volume droplets. Small volume droplet (20 µL) terminates on the thick dust layer (150 µm) at low surface inclination angle (1°). The quantity of dust picked up by the rolling droplet increases as the surface inclination angle increases. The amount of dust residues remaining on the rolling droplet path is relatively larger for the thick dust layer (150 µm) as compared to its counterpart of thin dust layer (50 µm).

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The Impact of 3D Printing Process Parameters on the Dielectric Properties of High Permittivity Composites

Designs ◽

10.3390/designs3040050 ◽

2019 ◽

Vol 3 (4) ◽

pp. 50 ◽

Cited By ~ 2

Author(s):

Athanasios Goulas ◽

Shiyu Zhang ◽

Darren A. Cadman ◽

Jan Järveläinen ◽

Ville Mylläri ◽

...

Keyword(s):

3D Printing ◽

Process Parameters ◽

Relative Permittivity ◽

Main Process ◽

Fused Filament Fabrication ◽

Layer Height ◽

Additive Manufacturing Technology ◽

The Impact ◽

Printing Speed ◽

Hatch Spacing

Fused filament fabrication (FFF) is a well-known and greatly accessible additive manufacturing technology, that has found great use in the prototyping and manufacture of radiofrequency componentry, by using a range of composite thermoplastic materials that possess superior properties, when compared to standard materials for 3D printing. However, due to their nature and synthesis, they are often a great challenge to print successfully which in turn affects their microwave properties. Hence, determining the optimum printing strategy and settings is important to advance this area. The manufacturing study presented in this paper shows the impact of the main process parameters: printing speed, hatch spacing, layer height and material infill, during 3D printing on the relative permittivity (εr), and loss tangent (tanδ) of the resultant additively manufactured test samples. A combination of process parameters arising from this study, allowed successful 3D printing of test samples, that marked a relative permittivity of 9.06 ± 0.09 and dielectric loss of 0.032 ± 0.003.

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