Reducing print time while minimizing loss in mechanical properties in consumer FDM parts

Abstract

Fused deposition modeling (FDM), one of various additive manufacturing (AM) technologies, offers a useful and accessible tool for prototyping and manufacturing small volume functional parts. Polylactic acid (PLA) is among the commonly used materials for this process. This study explores the mechanical properties and print time of additively manufactured PLA with consideration to various process parameters. The objective of this study is to optimize the process parameters for the fastest print time possible while minimizing the loss in ultimate strength. Design of experiments (DOE) was employed using a split-plot design with five factors. Analysis of variance (ANOVA) was employed to verify the model significance or otherwise. Once the model was developed, confirmation points were run to validate the model. The model was confirmed since the observations at the optimum were within the prediction interval with a confidence value of 95%. Then, the model was used to assess the ultimate strength and print time of FDM parts with consideration to nozzle diameter, the number of outer shells, extrusion temperature, infill percentage, and infill pattern. Recommendations are discussed in detail in this study to reduce print time without sacrificing significant part strength.