Optimization of fused deposition modeling (FDM) process parameters for flexural strength

The mechanical properties of functional parts created by fused deposition modelling (FDM) technique are influenced by process variables. The optimum process conditions can provide the desired properties of part. The aim of this study is an experimental investigation and optimization of FDM process variables using a hybrid statistical approach to attain desired flexural strength. The hybrid approach combines response surface methodology (RSM) and genetic algorithm (GA). The test samples are manufactured using FDM type 3D printer. The dimensions of samples considered according to American Society for Testing and Materials (ASTM) D790 standard. The acrylic butadiene styrene (ABS) of standard grade is considered as manufacturing material. Three process parameters varying at three levels are, layer thickness (0.1-0.2-0.3 mm), nozzle temperature (220-230 -240 degrees C) and print head speed (30-50-70 mm/s) considered. The experiments have been planned using face cantered composite design (FCCD) in Minitab software. The flexural strength test has been performed on tinnitus Olsen UTM machine. Further hybrid approach RSM-GA is used to optimize the process parameters. The predicted flexural strength by RSM-GA is found 58.34 MPa which is validated through experiment. The percentage prediction error and mean absolute deviation are also calculated for the scientific validation of results. Copyright (C) 2021 Elsevier Ltd. All rights reserved.