Optimization and experimental analysis of mechanical properties and porosity on FDM based 3D printed ABS sample

Abstract

A basic thermoplastic used in Fused Deposition Modeling (FDM) additive manufacturing methods is acrylonitrile–butadiene–styrene (ABS). However, the mechanical qualities of ABS components may be regulated by their porosity. This study aims to optimize the FDM process parameters to minimize porosity and increase ABS parts' tensile and compressive strengths. The experiment has been designed based on Taguchi's philosophy. The machining parameters have been considered as Extrusion multiplier, Temperature (oC), and Layer thickness (mm). The machining output has been analyzed using the mean effect plot. Furthermore, a hybrid optimization called grey relational analysis (GRA) and genetic algorithm (GA) is used to obtain the optimum parameter setting. the multi-optimization parameter setting is achieved as extrusion multiplier = 1, temperature = 240 °C, and layer thickness = 0.1 mm. The confirmation is also conducted to verify the optimum parameter setting. The findings showed that the suggested approach effectively enhanced the FDM process parameters for ABS components, leading to better mechanical characteristics and decreased porosity.