Optimization of build parameters of FDM 3D printing to reduce build time and increase its mechanical Strength

Abstract

During 3D printing part, many process parameters of the printer are required to be considered that affect the mechanical properties such as part strength. This research investigates the influence of layer height and print speed variations on the strength and quality of Fused Deposition Modelling (FDM) parts. The article shows the realized results of experiments and measurements of mechanical strengths, artifact dimensional accuracy, surface roughness and hatch distances. Proper selection of printing parameters is essential for achieving desired mechanical properties in 3D printed parts. The study employs Design of Experiments (DOEs) on different shaped geometries by using full factorial methodology to select the significant parameters for further research. A comprehensive test artifact is used to assess printer performance and dimensional limits. The test artifact, designed with various combinations of print speed and layer height, is subjected to 3D scanning to create 3D deviation maps, perform 3D comparisons, and calculate percentage error. Tensile tests and 3-point bend tests were conducted on test specimens, employing combinations of three distinct layer heights and print speeds. These tests were carried out following ASTM standards D 638 and D 790 to evaluate the tensile and flexure strengths, respectively. The outcomes indicate that extra fine layer heights and the lower print speeds yield higher strength and dimensional accuracy. Surface roughness and hatch distance analyses exhibit consistent patterns across both the tensile and 3-point bend tests. The results contribute to the exploration of FDM parameters for specific applications and the progress of additive manufacturing methodologies.