A response surface methodology investigation into the optimization of manufacturing time and quality for FFF 3D printed PLA parts

Purpose This study aims to examine the impact of specific printing factors, such as layer height, line width and build orientation, on the overall quality of fused filament fabrication (FFF) 3D printed structures. The project also intends to use response surface methodology (RSM) to maximize ultimate tensile strength (UTS) while lowering surface roughness and printing time. Design/methodology/approach This study used an FFF printer to fabricate samples of polylactic acid (PLA), which were then subjected to assessments of tensile strength and surface roughness. A tensile test was conducted under standardized conditions according to the ASTM D638 standard test method using the AG-50 kN Shimadzu Autograph. The Mitutoyo Surftest SJ-210, which utilizes a needle-tipped inductive method, was used to determine surface roughness. RSM was used for optimization. Findings This work provides useful insights into how the printing parameters affect FFF 3D printed structures, which may be used to optimize the printing process and improve PLA-based 3D printed products' qualities. The determined optimal values for building orientation, layer height and line width were 0°, 0.1 mm and 0.6 mm, respectively. The total desirability value of 0.80 implies desirable outcomes, and good agreement between experimental and projected response values supports the suggested models. Originality/value Previous RSM studies for 3D printing parameter optimization focused on mechanical properties or surface aspects, however, few examined multiple responses and their interactions. This study emphasizes the relevance of FFF parameters like line width, which are often overlooked but can dramatically impact printing quality. Mechanical properties, surface quality and printing time are integrated to comprehend optimization holistically.