Multi-objective optimization of fused filament fabrication (FFF) parameters for rice husk reinforced PLA composites

Fused Filament Fabrication (FFF) is a prominent additive manufacturing technique adept at creating intricate and dimensionally stable components. The integration of natural fillers, including rice husk fibers (RF), in polylactic acid (PLA) composites improves mechanical characteristics and sustainability. This study examines the influence of FFF process parameters and RF filler fraction on the mechanical characteristics of RF/PLA composites to identify the ideal printing conditions. RF/PLA composites were produced using melt mixing extrusion and FFF printing, incorporating RF loadings of 1.0 wt%, 3.0 wt%, and 5.0 wt%. The impact of layer thickness, nozzle temperature, and material percentage on tensile and flexural characteristics was examined. A singular value—multi-attribute performance index (MAPI) was derived from the diverse responses utilizing TOPSIS. The ideal parameters—0.2 mm layer thickness, 190°C nozzle temperature, and 1 % RF—produced superior mechanical performance, with material percentage accounting for 75 % of the total attributes. This study illustrates the feasibility of RF as a reinforcement in PLA composites for FFF, emphasizing the impact of process parameters on mechanical performance. The findings are crucial and relevant for optimizing FFF-printed natural fiber composites, since they have the potential to create innovative, environmentally sustainable products with optimal efficiency. • Fused filament fabrication method was employed to fabricate RF/PLA composites. • TOPSIS was used as a multi-criteria decision-making (MCDM) technique. • The ideal parameters are 0.2 mm LT, 190°C NT, and 1 % material percentage. • Material percentage (75 %) was found to be the highest contributing factor. • SEM image revealed good fiber matrix adhesion at interface.