A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> Surface Roughness <s> Abstract Rapid prototyping (RP) meets the current needs in the industry to shorten design cycles and improve the design quality. Fused deposition modelling (FDM) is one of the key technologies of RP. Various process parameters used in FDM affect the quality of the prototype. Work was undertaken to assess the influence of the parameters on the quality characteristics of the prototypes using Taguchi technique. This paper discusses the results of the study and the conclusions arrived from it. <s> BIB001 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> Surface Roughness <s> Surface finish and part deposition time are two important concerns in rapid prototyping (RP). These two concerns contradict with each other. Generally, a compromise is made between the two aspects pertaining to model building in RP. A compromise between these two contradicting issues can be achieved by using an adaptive slicing scheme; however, selection of a proper part deposition orientation will further provide an improved solution. Present work is an attempt towards obtaining an optimum part deposition orientation for fused deposition modeling process for enhancing part surface finish and reducing build time. Models for evaluation of average part surface roughness and build time are developed. A real coded genetic algorithm is used to obtain the optimum solution. Predictions of the present metzhodology are in good agreement with the result published earlier. Proposed methodology can be used to obtain the optimum deposition orientation for any type of component without selecting the preferred orientations. <s> BIB002 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> Surface Roughness <s> The objective of this research was to find the best combination of factor levels that minimized the surface roughness of prototyped samples from Fused Deposition Modeling (FDM). Two sets of experiments were conducted for that purpose; a two-level three-factor full factorial experiment and a three-level two-factor full factorial experiment. The parameters chosen for this research were model temperature, layer thickness and part fill style. The results obtained from both experiments were compared and analyzed in order to determine the best combination of factors that minimized the surface roughness of the specimens. The significant factors, their interactions and the optimum setting are presented in this paper <s> BIB003 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> Surface Roughness <s> Purpose – The following research seeks to focus on optimizing the fused deposition modeling (FDM) process of RP systems.Design/methodology/approach – Early stages of this study are based on the Taguchi method in establishing rapid prototyping building factors and their various levels. The ultimate tensile strength, dimension accuracy and surface roughness (SR), are analyzed. Through analysis of variance (ANOVA) and contribution approximation, significant building factors of each quality characteristic and optimal factors level combinations of each best quality characteristic are obtained. The main steps are setting the weight for each quality characteristic of the previous Taguchi method, obtaining the estimated multiple building quality characteristics through integrating the Gray theory, and obtaining a set of optimal building factors. Finally, the result is verified by the Gray theory and the technique for order preference by similarity to ideal solution (TOPSIS) evaluation method.Findings – It is prov... <s> BIB004 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> Surface Roughness <s> Abstract Fused deposition modeling (FDM) is an additive technology that suffers badly from low surface quality, requiring hand finishing for even the most basic levels of part quality. In this paper the authors study the influence of FDM machining parameters on acrylonitrile butadiene styrene (ABS) prototypes surface finish. The surface finish of products after the modification of extrusion parameters has been measured and processed through designed experiments. The chemical post-treatment does not require human intervention and has led to a significant improvement in surface finish at the expense of a negligible change in the prototype size. <s> BIB005 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> Surface Roughness <s> This paper describes an experimental design technique for determining the optimum surface finish and dimensional accuracy of a part built by the Fused Deposition Modeling (FDM) process. The design investigates the effect of the process parameters layer thickness, road width, raster angle and air gap on the surface finish and dimensional accuracy. Experiments were conducted using Taguchi's design of experiments with three levels for each factor. The results are statistically analyzed to determine the significant factors and their interactions. From the ANOVA analysis, it was found that the layer thickness and road width affect the surface quality and part accuracy greatly. Raster angle has little effect. But air gap has more effect on dimensional accuracy and little effect on surface quality. <s> BIB006 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> Surface Roughness <s> Fused deposition modelling (FDM) is one of rapid prototyping (RP) technologies which uses an additive fabrication approach. Each commercially available FDM model has different types of process parameters for different applications. Some of the desired parts require excellent surface finish as well as good tolerance. The most common parameters requiring setup are the raster angle, tool path, slice thickness, build orientation, and deposition speed. The purpose of this paper is to discuss the process parameters of FDM Prodigy Plus (Stratasys, Inc., Eden Prairie, MN, USA). Various selected parameters were tested and the optimum condition was proposed. The quality of the parts produced was accessed in terms of dimensional accuracy and surface finish. The optimum parameters obtained were then applied in the fabrication of the master pattern prior to silicone rubber moulding (SRM). These parameters would reduce the post processing time. The dimensional accuracy and surface roughness were analyzed using coordinate measuring machine (CMM) and surface roughness tester, respectively. Based on this study, the recommended parameters will improve the quality of the FDM parts produced in terms of dimensional accuracy and surface roughness for the application of SRM. <s> BIB007 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> Surface Roughness <s> This paper discusses optimization studies on process parameters for fused deposition modelling (FDM). Layer thickness, Orientation angle and fill angle are the process variables considered for optimization. Ultimate tensile strength, surface roughness, dimensional accuracy and manufacturing time were considered as response parameters. Experiments were designed using well known Taguchi's L9 orthogonal array, Taguchi's S/N ratio was used to identify optimum parameter values. Effectiveness of each parameter was investigated using analysis of variance. Furthur, performance of optimum conditions were validated by conducting verification experiment. <s> BIB008 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> Surface Roughness <s> Fused deposition modeling (FDM), a well known 3D printing technology is widely used in various sorts of industrial applications because of its ability to manufacture complex objects in the stipulated time. However, the proper selection of input process parameters in FDM is a tedious task that directly affects the part performance. Here, in this work, the research efforts have been made to optimize the FDM process parameters in order to find out the best parameter setting as per the mechanical and surface quality perspectives by using hybrid particle swarm and bacterial foraging optimization (PSO–BFO) evolutionary algorithm. Taguchi L18 orthogonal array was used for the development of acro-nitrile butadiene styrene based 3D components by considering layer thickness, support material, model interior and orientation as a process parameters. Further, the relationships among selected FDM process parameters and output responses such as hardness, flexural modulus, tensile strength and surface roughness were established by using linear multiple regression. Then, the effects of individual process parameters on selected response parameters were examined by signal to noise ratio plots. Finally, a multi-objective optimization of process parameters has been performed with hybrid PSO–BFO, general PSO and BFO algorithm, respectively. The overall results reveal that the layer thickness of 0.007 mm, support material type sparse, part orientation of 60\({^\circ }\) and model interior of high density helps in achieving desired performance level. <s> BIB009 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> Surface Roughness <s> Additive manufacturing technologies play an important role in Industry 4.0. One of the most prevalent processes is fused deposition modelling (FDM) due to its versatility and low cost. However, there is still a lack of standardization of materials and procedures within this technology. This work aims to study the relationship of certain operating parameters and the conditions of poly(lactic acid) (PLA) polymer with the results of the manufactured parts in dimensional terms, surface quality, and mechanical strength. In this way, the impact of some material characteristics is analyzed, such as the pigmentation of the material and the environmental humidity where it has been stored. The manufacturing parameter that relates to these properties has been the extrusion temperature since it is the most influential in this technology. The results are quite affected especially by humidity, being a parameter little studied in the literature. <s> BIB010 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> Surface Roughness <s> The present paper shows an experimental study on additive manufacturing for obtaining samples of polylactic acid (PLA). The process used for manufacturing these samples was fused deposition modeling (FDM). Little attention to the surface quality obtained in additive manufacturing processes has been paid by the research community. So, this paper aims at filling this gap. The goal of the study is the recognition of critical factors in FDM processes for reducing surface roughness. Two different types of experiments were carried out to analyze five printing parameters. The results were analyzed by means of Analysis of Variance, graphical methods, and non-parametric tests using Spearman’s ρ and Kendall’s τ correlation coefficients. The results showed how layer height and wall thickness are the most important factors for controlling surface roughness, while printing path, printing speed, and temperature showed no clear influence on surface roughness. <s> BIB011
Surface roughness is a widely used index of product quality. In most cases, surface roughness is often used as a technical requirement for mechanical products. Surface roughness increases the aesthetic view and is important to ensure proper function of very precise parts, for instance, sealing shafts and friction plates in the automobile sector. One of the limitations of the FDM process is poor surface quality due to the staircase effect, STL file resolution, and process parameters. The impacts of the staircase effect and STL file resolution depend on the shape complexity of a part (e.g., a curved surface is harder to obtain than a flat surface). The influence of process parameters on surface roughness not only depends on the shape of a part, but also on the setting of process parameters. The surface quality of an FDM built part can be improved by selecting an optimum combination of process parameters. Higher surface quality typically reduces post-processing cost. Vasudevarao et al.  investigated the influence of build orientation, layer thickness, raster width, air gap, and model temperature on the surface roughness. For this, parts produced by the Stratasys FDM 1650 machine for different combinations of process parameters were analyzed by half factorial design. The results of the experiment showed that low layer thickness and high build orientation reduced surface roughness, but other parameters were not significant for surface quality. According to Anitha et al. BIB001 , among layer thickness, raster width, and print speed, the layer thickness was found to be the most important parameter for surface quality. Raster width and print speed were almost equally significant for surface quality. Thrimurthulu et al. BIB002 also recommended a low layer thickness for high surface finishing. The impacts of three process parameters, namely, layer thickness, extrusion temperature, and visible surface, were investigated by Horvath et al. BIB003 to know the importance of those parameters for surface roughness, and a full factorial experimental design was used for the experiments. The results of the experimental study were aligned with the results found by Vasudevarao et al.  , where layer thickness was the most significant parameter, and the extrusion temperature was insignificant. They also recommended a fine raster width for reducing surface roughness. Wang et al. BIB004 studied the impact of six process parameters on surface roughness along with dimensional accuracy. Among the analyzed six parameters, the layer thickness was the most significant parameter for surface roughness, but build orientation in the Z-direction was the most significant parameter for dimensional accuracy. Galantucci et al. BIB005 experimentally investigated the impact of layer thickness, raster width, and tip size (nozzle diameter) on the roughness of the top and side surfaces. Their results indicated that layer thickness and raster width were significant for the side and top surface roughness of ABS printed parts. Other than dimensional accuracy, Nancharaiah et al. BIB006 also investigated the impact of four parameters (layer thickness, raster width, raster orientation, and air gap) on surface roughness. Their results showed that layer thickness and raster width had an influence on surface roughness and also recommended that the negative air gap degraded surface quality. Bakar et al. BIB007 analyzed layer thickness, shell width, and internal raster to determine the significance of those parameters for improving surface finishing. The surface quality of a top surface is better than the side surface. The shape of a part is important for reducing surface roughness, and a complex curvy surface reduces surface finishing. According to their paper, a wider raster width increases surface finishing as heat and high temperature easily affect the smaller raster. Like other researchers, they also recommended that low layer thickness is preferable for good surface quality. Akande  used a 3D Touch FDM machine and PLA as the filament material to produce cuboid-shaped specimens based on full factorial design, and investigated the importance of layer thickness, infill density and print speed for surface roughness. The lower level of each parameter was optimum for maximizing surface finishing. Along with many other part characteristics, Nidagundi et al. BIB008 analyzed surface roughness as well. In their research, the analyzed process parameters were build orientation, layer thickness, and raster orientation, and a Taguchi orthogonal array (L9) was applied to reduce the number of experiments. Based on the reduced experimental design, ABS printed parts were produced by a Julia 3D printer and the average R a value (surface roughness) was used as a measurement for optimum surface roughness. Their results indicated that 0.1 mm (minimum) layer thickness on the top and side surfaces, 0 • build orientation, and 0 • raster orientation were the settings for achieving optimum surface roughness. Raju et al. BIB009 also showed that layer thickness and build orientation were two significant parameters for surface quality. Valerga et al. BIB010 analyzed various PLA filament conditions to know their impact on surface quality, along with the dimensional accuracy and tensile strength of the FDM printed part. They considered extrusion temperature, humidity, and pigmentation color as variables. They drew a conclusion that a lack of pigmentation and a low extrusion temperature were preferable for better surface quality. Unlike most of the previously mentioned research, Pérez et al. BIB011 used a cylindrical-shaped specimen instead of a cuboid-shaped specimen. In their study, layer thickness, print speed, extrusion temperature, and shell thickness were the analyzed parameters. Their findings showed that low layer thickness was favored for good surface finishing, but extrusion temperature and print speed were insignificant. Short discussion and summary: High surface finishing can be achieved by selecting a low layer thickness because it helps reduce the staircase effect on the printed parts. Other than layer thickness, low extrusion temperature and print speed are preferable to achieve a higher print precision. A high extrusion temperature increases the fluidity of filament materials and further results in high dimensional deviation and surface roughness. Most results indicated that the surface finish of a top printed surface is better than the side surface for any setting of process parameters. Therefore, printing the shortest side of a part in the Z-direction is recommended for the FDM process to reduce the overall surface roughness. For an inclined part's orientation, neither horizontal nor vertical orientations increase surface roughness. Thus, if possible, it is best to avoid printing on an inclined orientation.