Parameter Tuning for Durable and Refined PMMA Filament 3D Printing

Abstract Extrusion of materials (MEX) in the form of filament has gained ground to produce customized components in various domains. In particular, poly(methyl methacrylate) (PMMA) material has shown promising results for customized biomedical devices. This investigation presents a stochastic strategy designed to enhance interlayer bonding in PMMA prints. Printing temperature, speed, and infill density were tested for bonding quality within a narrower experimental window, following a literature study conducted over a wider experimental range. Optimizing these parameters enabled the identification of conditions that significantly improve flexural strength and surface finish. The findings demonstrate the potential for finely tuned 3D printing conditions to produce durable, ready-to-use PMMA parts directly from the 3D printer. Process optimization showed that 100% Di, 250 °C Nt, and 40 mm/s Ps constitute the optimal parameter set, achieving maximum flexural strength alongside minimum surface roughness, with Fl-sb exceeding 48 MPa and Ra maintained below 10 µm.