Enhancing the tensile properties with minimal mass variation by revealing the effects of parameters in fused filament fabrication process

Abstract

The Fused Filament Fabrication is a revolutionary method for the manufacturing industry. However, there are still numerous challenges need to be tackled in order to standardize the procedure of printing process. In this study, the process parameters of line width, shell thickness, infill orientation and infill overlap, have been experimentally investigated over their affect on tensile strength properties and the mass of the produced samples. Design of experiments has been planned, conducted and evaluated using the Taguchi approach. A total of 25 combinations of the four printing parameters with five different settings have been set according to the L25 Orthogonal Array table. The sample parts have been printed via widely used type low-cost and open-source 3D printer. Afterwards, the printed samples are tested for their tensile strength. The best combinations of the parameters with relevant settings have been revealed by S/N Ratio analysis. In order to validate the statistical results, the sample with newly found combination has been manufactured. Then, the ANOVA has been applied in order to reveal the percentage contributions of parameters to the tensile behaviour. It has been concluded that infill overlap and orientation parameters are dominant factors over the ultimate tensile strength of the samples. As a widespread effect, generalized equations have been established and presented in order to calculate the occupied area by an overlap. By implementing the equations, the users will be able to configure their input parameters in behalf of increasing the tensile strength while controlling the material consumption.