Optimization of Fused Deposition Modelling Parameters using Design of Experiments

Abstract

Additive manufacturing (AM) has been proved to be a key competitor in the industrial market, as being able to adopt customizable designs with high levels of complexity. Fused Deposition Modelling (FDM) is currently one of the most widely used AM techniques, as it was shown to excel in terms of simplicity, cost effectiveness and time saving. A major factor, critical in enhancing any 3D print quality, is the selection of optimal process parameters. This study presents a statistical approach to optimize the manufacturing of a helical Polylactic (PLA) gear using FDM. Statistical approaches were applied to investigate the effect of layer height, infill percentage and build orientation on the printing time and material consumption was determined, on a virtually simulated model of the FDM process. Findings showed that the most significant factors influencing the print time were the layer height and percentage infill. Furthermore, it is concluded that the infill was the only significant parameter affecting the material consumption. The results of the conducted optimization study suggested that the optimum values of layer height, infill percentage and build orientation for minimum optimum print time and material consumption would be 0.25 mm, 20% and 50 degrees respectively.