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

Abstract

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.

Study of the Influence of Technological Parameters on Generating Flat Part with Cylindrical Features in 3D Printing with Resin Cured by Optical Processing

“…In both research and production, the quality obtained by the 3D printing process has an essential role in making parts or assemblies with the functional role [ 1 , 2 , 3 , 4 ]. At the same time, the use of this technology allows us to reduce manufacturing costs [ 5 , 6 ], as well as the level of pollution [ 7 , 8 , 9 , 10 ].…”

Synthetic Polymers for Organ 3D Printing

“…FDM is the layered deposition of molten thermoplastic polymers (i.e., thermoplastics) through one or more heated extrusion heads with a small orifice in a specific lay-down pattern ( Figure 2) [46,47]. It is a kind of specific extrusion-based 3D printing technology, known by the technical term 'thermoplastic extrusion'.…”

“…There is no theoretical restriction on the compositional gradients in all three dimensions for FDM technologies since multiple extrusion nozzles can be easily equipped, each with a different polymer. In the early 2000s, FDM technologies were the most popular industrial AM technologies worldwide [46,47].…”

“… Schematic illustration of fused deposition modeling (FDM) processes using synthetic polymers, such as acrylonitrile-butadiene-styrene copolymer (ABS), polyamide, polycarbonate, polyethylene and polypropylene: ( a ) one nozzle three-dimensional (3D) printing; ( b ) two nozzle 3D printing [ 46 , 47 ]. …”

Eight Weeks Later—The Unprecedented Rise of 3D Printing during the COVID-19 Pandemic—A Case Study, Lessons Learned, and Implications on the Future of Global Decentralized Manufacturing

“…All those in need of personal protection equipment could equally approach the makervsvirus community/hubs (as indicated by a blue symbol in the map below) by signing up on the website to place their request for equipment such as face shields or ear savers. As a Karlsruhe Institute of Technology (KIT) research group in AM technologies working on the optimization of the fused filament fabrication (FFF) printing process [4,5], we made the decision to participate in this makersvsvirus movement, and our FFF lab that had been closed due to the COVID-19 crisis re-opened within 24 h with a total of 14 FFF-printers supporting the production of PPE, see Figure 2. After a short ramp-up time required to test the different PPE models with the required process parameters, the lab was fully operational to run 24/7 for several weeks, producing the needed PPE in alternating shifts, thereby also minimizing the potential risk to our researchers who were working in the lab.…”