Optimization of Process Parameters in 3D Printing for Validation of Mechanical Properties in End Product

This study presents a systematic methodology for optimizing process parameters in Fused Deposition Modelling (FDM), a widely used additive manufacturing method, to validate the mechanical feasibility of end-use parts printed from Polylactic Acid (PLA). The core objective is to overcome the common limitation of 3D printed prototypes by demonstrating that printed components can achieve mechanical performance comparable to conventionally produced parts. The research focuses on three key process parameters: infill pattern (Line, Grid, Honeycomb), infill density (50%, 75%, 100%), and raster angle (0°, 45°, 90°), which significantly influence structural integrity, load distribution, layer bonding, and overall durability. An extensive experimental design was formulated, involving the fabrication of standard test specimens (tensile, flexural, Charpy impact) conforming to ASTM D638, D790, and D256 specifications. Two specimens were fabricated per parameter combination to enhance statistical reliability, undergoing mechanical testing to assess tensile strength, flexural modulus, and impact resistance. Data analysis was performed using a Taguchi L9 orthogonal array, an efficient statistical design of experiments (DOE) technique, to identify the most significant parameters and their optimal levels for improved mechanical properties. The optimized parameters were then applied to manufacture an easily accessible consumer item, which was subsequently tested to ensure repeatability and functional applicability. The results confirm that PLA, processed under optimized FDM conditions, provides repeatable and adequate mechanical properties for actual use, reinforcing 3D printing's potential as a cost-effective, customizable, and sustainable manufacturing solution for functional components.