Optimization of Print Quality and Mechanical Strength in Additive Manufacturing Using Different Nozzle Diameters

Additive Manufacturing (AM) has emerged as a transformative fabrication technology enabling rapid prototyping and custom production of complex geometries. Among various AM processes, Fused Deposition Modeling (FDM) remains the most widely adopted due to its simplicity, cost-effectiveness, and material versatility. However, achieving an optimal balance between print quality and mechanical performance continues to be a major challenge. This research investigates the influence of different nozzle diameters (0.2 mm, 0.4 mm, 0.6 mm) on the mechanical strength and surface quality of 3D- printed PLA components. Standardized tensile specimens were fabricated under controlled conditions, with constant parameters such as infill density, layer height, and printing speed. Tensile testing, surface roughness measurement, and dimensional accuracy evaluations were conducted. Statistical modeling using Response Surface Methodology (RSM) and Analysis of Variance (ANOVA) was applied to optimize parameters. Results indicate that smaller nozzles yield superior surface quality, while larger nozzles enhance interlayer adhesion and tensile strength. The optimal trade-off was found at a 0.4 mm nozzle diameter, achieving high strength and acceptable print quality. This study provides practical insights for additive manufacturing users seeking to optimize process performance.