Experimental study and optimizing the FDM process using war strategy optimization technique to enhance mechanical properties and surface quality of the PLA thermoplastic

Fused deposition modelling (FDM) is extensively utilized in aerospace and biomedical industries for creating intricate and complex parts and prototypes. The mechanical properties of 3D printed components heavily rely on selecting the appropriate process parameters. This study aims to investigate the effects of process parameters, such as infill pattern type, nozzle diameter, and nozzle temperature, on the mechanical properties and surface roughness of FDM printed parts. Analysis of variance was employed to assess the effects of each parameter and identify the significant ones. The results revealed that nozzle diameter has the most influence on tensile behavior, while infill pattern affects impact strength and surface roughness the most. The process parameters were optimized to achieve lower surface roughness and maximum tensile and impact strength, as well as elongation at break, for the printed parts. A novel optimization technique called war strategy optimization (WSO) was implemented in this investigation, using regression correlations as objective functions. For each objective function, exclusive optimal parameter settings were proposed.