Optimization of 3D Printing Parameters for Enhanced Surface Quality and Wear Resistance

Abstract

In recent years, there has been a growing interest in the field of 3D printing technology. Among the various technologies available, fused deposition modeling (FDM) has emerged as the most popular and widely used method. However, achieving optimal results with FDM presents a significant challenge due to the selection of appropriate process parameters. Therefore, the objective of this research was to investigate the impact of process parameters on the tribological and frictional behavior of acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) 3D-printed parts. The design of experiments (DOE) technique was used considering the input design parameters (infill percentage and layer thickness) as variables. The friction coefficient values and the wear were determined by experimental testing of the polymers on a universal tribometer employing plane friction coupling. Multi-response optimization methodology and analysis of variance (ANOVA) were used to highlight the dependency between the coefficient of friction, surface roughness parameters, and wear on the process parameters. The optimization analysis revealed that the optimal 3D printing input parameters for achieving the minimum coefficient of friction and linear wear were found to be an infill percentage of 50% and layer thickness of 0.1 mm (for ABS material), and an infill percentage of 50%, layer thickness of 0.15 mm (for PLA material). The suggested optimization methodology (which involves minimizing the coefficient of friction and cumulative linear wear) through the optimized parameter obtained provides the opportunity to select the most favorable design conditions contributing to a more sustainable approach to manufacturing by reducing overall material consumption.

Change in the Low-Cycle Performance on the 3D-Printed Materials ABS, ASA, HIPS, and PLA Exposed to Mineral Oil

“…A fill of 100% should enable it not to penetrate the inner layers of the structure and, despite the higher material consumption, increase the strength of the fabricated parts. The linear infill pattern allows the material to be applied in parallel lines, which should lead to a higher tensile strength along the infill axis [ 20 , 21 ].…”

“…There are also articles in which cyclic tests were used to evaluate the strength. Articles [ 21 , 22 ] focused on PLA material and its modified counterpart, where it was shown that, under the same loading conditions, the fatigue life of the 3D-printed samples was similar. Additionally, the presence of porosity in the material was demonstrated by conducting SEM (scanning electron microscope) analyses [ 23 , 24 ].…”

Influence of Post-Processing on the Degree of Conversion and Mechanical Properties of 3D-Printed Polyurethane Aligners

“…Each protocol serves to improve the overall finish, mechanical integrity, and cleanliness of the printed objects, ensuring they meet the required standards for various applications, while also potentially reducing the presence of defects that could compromise their functionality and longevity [ 37 , 38 , 39 , 40 , 41 , 42 , 43 , 44 ].…”

Innovative Strategies for Technical-Economical Optimization of FDM Production

“…The printing parameters affecting the mechanical properties and production cost of 3D-printed samples are the layer thickness (0.10 mm/0.15 mm/0.20 mm) and infill percentage (50%/75%/100%). The mechanical properties investigated were previously determined by the authors of the present work, namely tensile strength [ 6 , 9 , 28 ], compression strength [ 8 ], flexural strength [ 7 , 9 ], impact strength [ 29 ], and hardness [ 28 , 30 ].…”