Effect of Process Parameters on Energy Consumption, Physical, and Mechanical Properties of Fused Deposition Modeling

Abstract

The application of the fused deposition modeling (FDM) additive manufacturing process has increased in the production of functional parts across all industries. FDM is also being introduced for industrial tooling and fixture applications due to its capabilities in building free-form and complex shapes that are otherwise challenging to manufacture by conventional methods. However, there is not yet a comprehensive understanding of how the FDM process parameters impact the mechanical behavior of engineered products, energy consumption, and other physical properties for different material stocks. Acquiring this information is quite a complex task, given the large variety of possible combinations of materials–additive manufacturing machines–slicing software process parameters. In this study, the knowledge gap is filled by using the Taguchi L27 orthogonal array design of experiments to evaluate the impact of five notable FDM process parameters: infill density, infill pattern, layer thickness, print speed, and shell thickness on energy consumption, production time, part weight, dimensional accuracy, hardness, and tensile strength. Signal-to-noise (S/N) ratio analysis and analysis of variance (ANOVA) were performed on the experimental data to quantify the parameters’ main effects on the responses and establish an optimal combination for the FDM process. The novelty of this work is the simultaneous evaluation of the effects of the FDM process parameters on the quality performances because most studies have considered one or two of the performances alone. The study opens an opportunity for multiobjective function optimization of the FDM process that can be used to effectively minimize resource consumption and production time while maximizing the mechanical and physical characteristics to fit the design requirements of FDM-manufactured products.

Influence of process parameters on mechanical strength, build time, and material consumption of3Dprinted polylactic acid parts

“…The thickness of the layer purely depends upon the extrusion nozzle diameter and must not exceed 80% of the nozzle diameter. [ 4 ] Therefore, to investigate the interaction of nozzle diameter with different layer heights for part strength, the present investigation includes nozzle diameters (0.4, 0.6, and 0.8 mm) with layer heights (0.20, 0.25, and 0.30 mm). In a study [ 30 ] triangular raster pattern has been suggested for bio‐implant/tissue 3D printed parts while comparing the mechanical response with grid and tri‐hexagonal raster pattern filled 3D parts.…”

“…FDM method continuously faces a number of challenges due to its limitations with the mechanical strength of the part, surface quality, dimensional accuracy, and build time. [ 4 ] Thus, numerous researchers worked on improving the FDM process by developing new FDM feedstock materials, optimizing the FDM process parameters, analyzing the mechanical, thermal, and rheological behavior of build parts. In the FDM process, the feedstock filaments used can be nontoxic, biodegradable, and cost‐effective, thus, the FDM process is safe and eco‐friendly.…”

How generalisable are material extrusion additive manufacturing parameter optimisation studies? A systematic review

“…PHV can also influence the defects listed: Circularity, Geometrical accuracy, Surface Roughness, Shrinking, and Warping. ↑ [ 25 , 31 , 37 , 53 , 54 , 61 , 65 , 72 , 73 , 88 , 99 , 100 , 109 , 114 , 116 , 117 ] ↓ [ 32 , 34 , 36 , 68 , 71 , 76 , 92 , 106 , 108 , 112 , 118 ] Air Gap (AG) The measured lateral distance between the centre points of deposited adjacent filament strands. AG can also influence the defects listed: Geometrical accuracy, Porosity, and Surface Roughness.…”

Characterization and parametric optimization of additive manufacturing process for enhancing mechanical properties

“…According to Enemuoh et al. [ 15 ], infill density, followed by layer height, print speed, and fill pattern, has high potential on the tensile strength of the FDM component. Christiyan et al.…”