Analysis and Optimization of Dimensional Accuracy and Porosity of High Impact Polystyrene Material Printed by FDM Process: PSO, JAYA, Rao, and Bald Eagle Search Algorithms

Abstract

High impact polystyrene (HIPS) material is widely used for low-strength structural applications. To ensure proper function, dimensional accuracy and porosity are at the forefront of industrial relevance. The dimensional accuracy cylindricity error (CE) and porosity of printed parts are influenced mainly by the control variables (layer thickness, shell thickness, infill density, print speed of the fused deposition modeling (FDM) process). In this study, a central composite design (CCD) matrix was used to perform experiments and analyze the complete insight information of the process (control variables influence on CE and porosity of FDM parts). Shell thickness for CE and infill density for porosity were identified as the most significant factors. Layer thickness interaction with shell thickness, infill density (except for CE), and print speed were found to be significant for both outputs. The interaction factors, i.e., shell thickness and infill density, were insignificant (negligible effect) for both outputs. The models developed produced a better fit for regression with an R2 equal to 94.56% for CE, and 99.10% for porosity, respectively. Four algorithms (bald eagle search optimization (BES), particle swarm optimization (PSO), RAO-3, and JAYA) were applied to determine optimal FDM conditions while examining six case studies (sets of weights assigned for porosity and CE) focused on minimizing both CE and porosity. BES and RAO-3 algorithms determined optimal conditions (layer thickness: 0.22 mm; shell thickness: 2 mm; infill density: 100%; print speed: 30 mm/s) at a reduced computation time equal to 0.007 s, differing from JAYA and PSO, which resulted in an experimental CE of 0.1215 mm and 2.5% of porosity in printed parts. Consequently, BES and RAO-3 algorithms are efficient tools for the optimization of FDM parts.

Simulation Analysis of Injection Moulding Process for Fidget Spinner

“…HIPS was selected due to its versatility, economical nature, and impact resistance properties (Table 1). It is known for being easy to fabricate and machine, making it a suitable choice for this study [15]. HIPS is preferred for low-strength structural applications, readily available, and relatively cheap.…”

Novel Electromagnetic Characterization Methods for New Materials and Structures in Aerospace Platforms

“…It is moderately priced, easily molded and machinable [ 23 ]. High Impact Polystyrene (HIPS), Polyethylene terephthalate glycol (PETG) and Polylactic acid (PLA): Materials typically used for 3D printing using the Fused Deposition Modeling process (FDM) [ 24 , 25 ]. FDM process can be used to fabricate complex geometries or internal structures and has been widely applied in many industries, such as the aerospace industry [ 26 ].…”

“…High Impact Polystyrene (HIPS), Polyethylene terephthalate glycol (PETG) and Polylactic acid (PLA): Materials typically used for 3D printing using the Fused Deposition Modeling process (FDM) [ 24 , 25 ].…”

Parametric Optimization of FDM Process for PA12-CF Parts Using Integrated Response Surface Methodology, Grey Relational Analysis, and Grey Wolf Optimization

“…The results showed that all approaches performed similarly and provided optimal settings. Various other studies [ 19 , 20 , 21 , 22 , 23 , 24 , 25 ] have explored the optimization of process parameters in additive manufacturing using hybrid approaches. These studies utilized various intelligent algorithms to attain optimal results for specific objectives related to their respective problems.…”