Fused deposition modeling (FDM) is one of the most popular additive manufacturing technologies for various engineering applications. FDM process has been introduced commercially in early 1990s by Stratasys Inc., USA. The quality of FDM processed parts mainly depends on careful selection of process variables. Thus, identification of the FDM process parameters that significantly affect the quality of FDM processed parts is important. In recent years, researchers have explored a number of ways to improve the mechanical properties and part quality using various experimental design techniques and concepts. This article aims to review the research carried out so far in determining and optimizing the process parameters of the FDM process. Several statistical designs of experiments and optimization techniques used for the determination of optimum process parameters have been examined. The trends for future FDM research in this area are described.

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Optimization of fused deposition modeling process parameters: a review of current research and future prospects

This study presents the influences of key processing parameters on the resulting material properties of fused-deposition-modeled (FDM) polylactic acid (PLA) components tested in torsion. A reduced experimental matrix was produced through the use of a Taguchi L9 orthogonal array with three parameters at three levels each. The processing parameters included the layer thickness, infill density, and postprocessing heat-treatment time at 100°C. Testing of components at varying times is conducted to facilitate heat-treatment time testing range and show the effects of prolonged heating. The layer thickness and infill are tested across the entire useful range available for the FDM machine used. Shear stress–strain response curves are acquired and average ultimate shear strength, 0.2% yield strength, proportional limit, shear modulus, and fracture strain are calculated for each run. An analysis of results via regression analysis is used to determine influences levels of parameters of the mechanical properties. The layer thickness and infill density are shown to be of high importance when optimizing for strength, with heat-treatment implementation slightly improving the resulting properties. Ductility is mainly affected by infill and heat treatment, with layer thickness having only a slight effect on the fracture strain achieved. Recommendations are made based on results of a method to optimize for either strength or ductility and how to compromise between recommended settings when a balance between the two is desired. The ability to produce parts with mechanical properties at or near those of bulk PLA is shown.

Mechanical Property Optimization of FDM PLA in Shear with Multiple Objectives

Purpose




This paper aims to present the influences of several production variables on the mechanical properties of specimens manufactured using fused deposition modeling (FDM) with polylactic acid (PLA) as a media and relate the practical and experimental implications of these as related to stiffness, strength, ductility and generalized loading.




Design/methodology/approach




A two-factor-level Taguchi test matrix was defined to allow streamlined mechanical testing of several different fabrication settings using a reduced array of experiments. Specimens were manufactured and tested according to ASTM E8/D638 and E399/D5045 standards for tensile and fracture testing. After initial analysis of mechanical properties derived from mechanical tests, analysis of variance was used to infer optimized production variables for general use and for application/load-specific instances.




Findings




Production variables are determined to yield optimized mechanical properties under tensile and fracture-type loading as related to orientation of loading and fabrication.




Practical implications




The relation of production variables and their interactions and the manner in which they influence mechanical properties provide insight to the feasibility of using FDM for rapid manufacturing of components for experimental, commercial or consumer-level use.




Originality/value




This paper is the first report of research on the characterization of the mechanical properties of PLA coupons manufactured using FDM by the Taguchi method. The investigation is relevant both in commercial and consumer-level aspects, given both the currently increasing utilization of 3D printers for component production and the viability of PLA as a renewable, biocompatible material for use in structural applications.

An approach for mechanical property optimization of fused deposition modeling with polylactic acid via design of experiments

Investigating the effect of fused deposition modeling processing parameters using Taguchi design of experiment method

Optimization of fused deposition modeling process parameters for dimensional accuracy using I-optimality criterion

Aiming at such performance indexes in fused deposition modeling (FDM) as dimensional error (DE) and warpage deformation (WD), and selecting four process parameters, wire-width compensation (A), extrusion velocity (B), filling velocity (C), and layer thickness (D), as controlling factors, this paper optimized the four process parameters by means of Taguchi method combined with fuzzy comprehensive evaluation. The optimization results show that the parameter with the most significant influence on the performance indexes is A, followed by B, D, and C, and that the optimum combination of the process parameters is A1B1C2D3.

Jin Wen Zhang

Papers

Process-Parameter Optimization for Fused Deposition Modeling Based on Taguchi Method