A review of process parameter optimization to enhance the performance of mechanical properties in Fused Filament Fabrication

Abstract Additive Manufacturing (AM), known as 3D printing, finds application in many fields since it is able to produce complex geometries with the least wastage of materials. Of all the AM processes, Fused Filament Fabrication (FFF) is the most popular because of its low cost and versatility in available materials. The mechanical properties of 3D-printed components including tensile strength, flexural strength, impact resistance, and surface finish, are highly dependent on various process parameters. It is, therefore, imperative to study and optimize these parameters for the improvement of structural integrity and functional performance of printed parts. This review analyses key process parameters affecting the mechanical properties of 3D printing. The review discusses critical factors such as layer thickness, printing speed, nozzle and bed temperature, build orientation, raster angle, infill density, and infill pattern in detail. The study presents the point of view of the influence of these parameters on mechanical performance, where examples of some recent work discussed show that certain adjustments can result in improvements in tensile strength, dimensional accuracy, and surface quality. The role of post-processing techniques like heat treatment, annealing, and chemical smoothing in enhancing the mechanical properties is also briefly discussed. Moreover, some interdynamics between the parameters are discussed to give an insight into the overall print quality concerning their interaction. The findings of this review serve as a guide for researchers, engineers, and manufacturers to optimize 3D printing parameters, enabling the production of mechanically robust and reliable components suitable for industrial applications.