Process parameter optimization of fused filament fabrication – 3D printing with PETG: a multi-objective approach using the matrix method

Purpose This paper aims to optimize the process parameters of fused filament fabrication (FFF) to promote the sustainable manufacturing of the components. Design/methodology/approach In this paper, six key process parameters, such as extrusion temperature, print speed, infill density, infill pattern, layer thickness and build orientation, are identified as influential factors in the mechanical performance and sustainability matrices of the polyethylene terephthalate glycol (PETG) printed parts. Taguchi’s design of experiments was used to assess the impact of each parameter on six critical response variables: tensile strength, flexural strength, surface roughness, time to print, energy and material consumption. Statistical methods such as analysis of means and analysis of variance were performed to systematically evaluate the influence of process parameters of FFF on responses. Furthermore, a new matrix-based method is used to optimize all six responses simultaneously. Findings The major findings include that layer thickness and infill density are the two major parameters that influence the responses considered in the study, followed by print speed, infill pattern, build orientation and extrusion temperature. The optimum parameters obtained by the matrix method are validated by experiment, and the results are promising, demonstrating a significant improvement in energy efficiency and material performance, aligning with sustainable manufacturing goals. Originality/value Using a matrix-based multi-response optimization method, mechanical characteristics and energy-efficient PETG components can be printed, leading to sustainable manufacturing.