Optimizing fused filament fabrication process parameters for quality enhancement of PA12 parts using numerical modeling and taguchi method

Abstract

Fused Filament Fabrication (FFF) is an Additive Manufacturing (AM) technique implemented in widespread applications and several components. Despite its benefits, the physics behind the FFF process is quite complicated and requires fast heating and cooling rate of the extruded material. Consequently, the component experiences extremely non-uniform internal stresses that might lead to warpage deformation. It is necessary to optimize the printing parameters as they are associated with the warpage deformation of printed components. One method for achieving this target is conducting physical tests that offer precise findings, but it is an expensive strategy. Another approach is to simulate the printing parameters with special software. In this work, Digimat-AM was employed to develop a thermomechanical Finite Element Model of the FFF to simulate parts made of Polyamide12 (PA12). An L27 orthogonal array, a tool of the Taguchi orthogonal array, and an analysis of variance (ANOVA) were used to estimate the impact of five printing parameters and their ultimate levels to improve the dimension's quality by minimizing the warpage deformation. Results showed a significant impact of the bed temperature on the warpage deformation values. The infill density contributed 2.84% in reducing the warpage deformation, and the rest of the parameters' contribution was less than 1% for each.