A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> Abstract Abstract Tensile strength, modulus of rupture, and impact resistance were found for different layer orientations of ABS rapid prototype solid models. The samples were fabricated by a Stratasys rapid prototyping machine in five different layer orientations. The 0° orientation where layers were deposited along the length of the samples displayed superior strength and impact resistance over all the other orientations. The anisotropic properties were probably caused by weak interlayer bonding and interlayer porosity. <s> BIB001 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> Rapid Prototyping (RP) technology has been advanced to fabricate initial prototypes from various materials. Stratasys’ Fused Deposition Modeling (FDM) is one of the typical RP processes that provide functional prototypes of ABS plastic. In order to predict the behavior of final ABS parts, it is critical to understand the material properties of the raw FDM process material, and the effect that FDM build parameters have on composite material properties. In this paper, we seek t the properties of ABS parts fabricated by the FDM 1650. Using the Design of Experiment (DOE) approach, the process parameters of FDM, such as raster orientation, air gap, bead width, color, and model temperature were examined. Tensile strengths of crisscross specimens, [45 °/-45°], cross specimens, [0 °/90°], and directionally fabricated tensile specimens ([0°] and [90 °]) were measured and compared with the injection molded FDMABS P400 material. For the FDM parts made with a –0.003” air gap, the typical tensile strength ranged between 65 percent and 72 percent of the strength of injection molded ABS P400. From the experiment s, several build rules for designing FDM parts were obtained. <s> BIB002 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> In this study, the Taguchi method, a powerful tool to design optimization for quality, is used to find the optimal process parameters for fused deposition modeling (FDM) rapid prototyping machine that was used to produce acrylonitrile butadiene styrene (ABS) compliant prototype. An orthogonal array, main effect, the signal-to-noise (S/N) ratio, and analysis of variance (ANOVA) are employed to investigate the process parameters in order to achieve optimum elastic performance of a compliant ABS prototype so as to get maximum throwing distance from the prototype. Through this study, not only can the optimal process parameters for FDM process be obtained, but also the main process parameters that affect the performance of the prototype can be found. Experiments were carried out to confirm the effectiveness of this approach. From the results, it is found that FDM parameters, i.e. layer thickness, raster angle and air gap significantly affect the elastic performance of the compliant ABS prototype. The optimum levels of parameters at different angle of displacement are also presented. © 2005 Elsevier B.V. All rights reserved. <s> BIB003 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> Most rapid prototyping (RP) technologies apply a layered manufacturing (LM) process to efficiently fabricate 3D physical models. However, a critical drawback that reduces the surface quality of the RP parts occurs by utilizing LM. Hence, topics related to surface roughness have been a key issue in RP. In this paper, a new approach to model surface roughness in fused deposition modeling (FDM) is proposed. Based on actual surface roughness distributions of FDM parts, a theoretical model to express surface roughness distribution according to changes in surface angle is presented by considering the main factors that crucially affect surface quality. The proposed expression is verified by implementation and comparison with empirical data. Also, the effectiveness of the main factors is analyzed and discussed. <s> BIB004 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <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> BIB005 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <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> BIB006 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> Fused deposition modeling (FDM) has evolved as one of the fastest growing layer manufacturing (LM) technology because of its capability to build even functional plastic parts with geometrical complexity in a reasonable time period. The quality of the production process depends on various process parameters, the most important of them being layer thickness (h), raster angle (θ), orientation (φ), contour width (c) and part raster width (w). In the present study, the influence of these parameters on two process quality parameters, namely, build time and the support material volume are studied on a rotational part modeled on a FDM 200mc machine. A 25 full factorial Design of Experiments (DOE) methodology was employed and the results for build time and support material volume of the 32 experiments were analyzed using Design Expert®. Analysis of variance (ANOVA) was done and based on the ANOVA results the model equation for the two quality parameters in both coded and original factors has been developed. Comments on the results obtained and interaction effects are included at the end of the paper. <s> BIB007 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> This paper presents a study of dynamic mechanical properties of Fused Deposition Modelling (FDM) rapid prototyping processed material Acrylonitrile butadiene styrene (ABS). It involves the measurement of modulus and damping properties of the material as it is deformed under periodic stress. In this study, frequency sweep is performed in DMA 2980 equipment to determine modulus, damping and viscosity values. The effect of FDM process parameters of built style, raster width, and raster angle over these properties is investigated. Frequency sweep experiment is done with the range of 10 Hz to 100 Hz in three different isothermal temperatures. The effect of temperature over these properties is also determined. Results show that solid normal built style gives more strength when compared to double dense and sparse built styles. It is also found that the loss modulus increases with increase in temperature, but viscosity values decrease with the increase in the temperature. KeywordsAcrylonitrile Butadiene Styrene (ABS), Dynamic Mechanical Analysis, Fused Deposition Modelling, Rapid Prototyping. <s> BIB008 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> The mechanical properties of a product made in Fused Deposition Modelling (FDM) rapid prototyping are strongly dependant on process parameters selected during part fabrication. Acrylonitrile butadiene styrene (ABS) is a common material used in FDM systems. The advantages of ABS include high strength and rigidity with toughness and these properties make it one of the most common thermoplastics used in engineering applications. This paper describes an experimental investigation of dynamic stressstrain response of ABS parts made by fused deposition modelling for three different part build orientations. Currently there is limited research available for this aspect of ABS material processed by FDM systems. The high strain rate compression tests were performed using a Split Hopkinson Pressure Bar apparatus to determine the dynamic stress-strain response and results were compared with quasi-static behaviour of the same specimens. <s> BIB009 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> Fused deposition modelling (FDM) is the most extended additive manufacturing technique up to date. In FDM, a thermoplastic material is extruded through a nozzle to form layers, and the final geometry is the result of consecutive superimposed layers. However, it is difficult to obtain an adequate dimensional accuracy for some applications due to the characteristics of the process. This paper proposes a method for increasing accuracy of the distance between parallel faces on FDM manufactured prismatic parts, consisting in replacing the theoretical values of CAD model dimensions by new optimized values. For this purpose, a model has been developed for predicting the dimensions of the manufactured parts, based on design characteristics. Particularly, this work has used an artificial neural network combined with an optimization algorithm, to determine the optimal dimensional values for the CAD model. Subsequently, CAD model is redesigned according to the dimensions provided by the optimization algorithm, and the part is manufactured. The results show that the application of this methodology allows for a reduction in manufacturing error of approximately 50 % for external dimensions and 30 % for internal dimensions. <s> BIB010 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> This paper presents the research done to determine the functional relationship between process parameters and tensile strength for the fused deposition modelling (FDM) process using the group method for data modelling for prediction purposes. An initial test was carried out to determine whether part orientation and raster angle variations affect the tensile strength. It was found that both process parameters affect tensile strength response. Further experimentations were carried out in which the process parameters considered were part orientation, raster angle, raster width and air gap. The process parameters and the experimental results were submitted to the group method of data handling (GMDH), resulting in predicted output, in which the predicted output values were found to correlate very closely with the measured values. Using differential evolution (DE), optimal process parameters have been found to achieve good strength simultaneously for the response. The mathematical model of the response of the tensile strength with respect to the process parameters comprising part orientation, raster angle, raster width and air gap has been developed based on GMDH, and it has been found that the functionality of the additive manufacturing part produced is improved by optimizing the process parameters. The results obtained are very promising, and hence, the approach presented in this paper has practical application for the design and manufacture of parts using additive manufacturing technologies. <s> BIB011 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> Fused deposition modeling (FDM) is gaining distinct advantages because of its ability to fabricate the 3D physical prototypes without the restrictions of geometric complexities, while when it comes to accuracy and efficiency, the advantages of FDM is not distinct, and so how to improve them is worthy of study. Focusing on process parameter optimization, such parameters as line width compensation, extrusion velocity, filling velocity, and layer thickness are selected as control factors, input variables, and dimensional error, warp deformation, and built time are selected as output responses, evaluation indexes. Experiment design is assigned according to uniform experiment design, and then the three output responses are converted with fuzzy inference system to a single comprehensive response. The relation between the comprehensive response and the four input variables is derived with second-order response surface methodology, the correctness of which is further validated with artificial neural network. Fitness function is created using penalty function and is solved with genetic algorithm toolbox in Matlab software. With confirmation test, the results are obtained preferring to the results of the experiment 1 with the best comprehensive response among the 17 experiment runs, which confirms that the proposed approach in this study can effectively improve accuracy and efficiency in the FDM process. <s> BIB012 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> This study presents the influences of key processing parameters on the resulting material properties of fused-deposition-modeled (FDM) polylactic acid (PLA) components tested in torsion. A reduced experimental matrix was produced through the use of a Taguchi L9 orthogonal array with three parameters at three levels each. The processing parameters included the layer thickness, infill density, and postprocessing heat-treatment time at 100°C. Testing of components at varying times is conducted to facilitate heat-treatment time testing range and show the effects of prolonged heating. The layer thickness and infill are tested across the entire useful range available for the FDM machine used. Shear stress–strain response curves are acquired and average ultimate shear strength, 0.2% yield strength, proportional limit, shear modulus, and fracture strain are calculated for each run. An analysis of results via regression analysis is used to determine influences levels of parameters of the mechanical properties. The layer thickness and infill density are shown to be of high importance when optimizing for strength, with heat-treatment implementation slightly improving the resulting properties. Ductility is mainly affected by infill and heat treatment, with layer thickness having only a slight effect on the fracture strain achieved. Recommendations are made based on results of a method to optimize for either strength or ductility and how to compromise between recommended settings when a balance between the two is desired. The ability to produce parts with mechanical properties at or near those of bulk PLA is shown. <s> BIB013 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> In this study, a preliminary effort was undertaken to represent the mechanical properties of a 3D printed specimen as a function of layer number, thickness and raster orientation by investigating the correlation between the mechanical properties of parts manufactured out of ABS using Fused Filament Fabrication (FFF) with a commercially available 3D printer, Makerbot Replicator 2x, and the printing parameters, such as layer thickness and raster orientation, were considered. Specimen were printed at raster orientation angles of 0°, 45° and 90°. Layer thickness of 0.2 mm was chosen to print specimens from a single layer to 35 layers. Samples were tested using an MTS Universal Testing Machine with extensometer to determine mechanical strength characteristics such as modulus of elasticity, ultimate tensile strength, maximum force and maximum elongation as the number of layers increased. Results showed that 0° raster orientation yields the highest mechanical properties compared to 45° and 90° at each individual layer. A linear relationship was found between the number of layers and the maximum force for all three orientations, in other words, maximum force required to break specimens linearly increased as the number of layers increased. The results also found the elastic modulus and maximum stress to increase as the number of layers increased up to almost 12 layers. For samples with more than 12 layers, the elastic modulus and maximum stress still increased, but at a much slower rate. These results can help software developers, mechanical designers and engineers reduce manufacturing time, material usage and cost by eliminating unnecessary layers that do not increase the ultimate stress of the material by improving material properties due to the addition of layers.Copyright © 2015 by ASME <s> BIB014 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <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> BIB015 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> In fused deposition modeling (FDM) additive manufacturing process, it is often difficult to determine the actual levels of process parameters in order to achieve the best dynamic mechanical properties of FDM manufactured part. This is mainly due to the large number of FDM parameters and a high degree of interaction between the parameters affecting such properties. This requires a large number of experiments to be determined. This paper presents a study on the influence of six FDM process parameters (layer thickness, air gap, raster angle, build orientation, road width, and number of contours) on the dynamic mechanical properties of the FDM manufactured parts using the fraction factorial design. The most influential parameters were statistically obtained through the analysis of variance (ANOVA) technique, and the results indicate that the layer thickness, the air gap, and the number of contours have the largest impact on dynamic mechanical properties. The optimal parameters for maximum dynamic mechanical properties were found to be layer thickness of 0.3302 mm, air gap of 0.00 mm, raster angle of 0.0°, build orientation of 0.0°, road width of 0.4572 mm, and 10 contours. Finally, a confirmation experiment was performed using optimized levels of process parameters, which showed good fit with the estimated values. <s> BIB016 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> In this paper, we investigate the print orientation effects on the macrostructure, the mechanical and thermal properties, and the strain field behavior of ULTEM® 9085 using a Stratasys Fused deposition modeling (FDM) 400 Printer. The tensile strength, failure strain, Poisson’s ratio, coefficient of thermal expansion and modulus were all shown to vary significantly depending on the build orientation of identical dogbones. FDM parts ranged in strength from 46 to 85% of strengths attainable from comparable injection-molded parts. The coefficient of variation (CV) increased from 2 to 13% as the primary layer orientation deviated from the primary load direction. CAT scan and SEM were employed to relate the corresponding macrostructure to the mechanical response of the material along the parts’ 3-primary directions, using digital image correlation (DIC). The fracture surfaces of these parts further suggest that 3D FDM materials behave more like laminated composite structures than isotropic cast resins and therefore design allowables should reflect actual part build configurations. <s> BIB017 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> The mechanical properties of a fused deposition modeling (FDM) process product are greatly influenced by many process parameters. The identified parameters namely deposition orientation, layer thickness and deposition style, raster width, and raster gap are more significant factors contributing to the strength of a FDM product. In this paper, tensile strength, flexural strength, and impact strength are considered as three evaluation indexes to characterize the mechanical properties of a FDM part. An experimental research approach based on the Taguchi method was presented and some special specimens were designed. The influences of the five parameters on the three evaluation indexes were analyzed by the use of analysis of variance (ANOVA). Finally, based on the gray relational analysis, a set of optimal process parameter combination was obtained to optimize comprehensive mechanical properties of FDM parts. <s> BIB018 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> Abstract Acrylonitrile–butadiene–styrene (ABS) is one of the most widely usedindustrial thermoplastic and it is the most common material used in fused deposition modeling (FDM) technology. While FDM is one of the most used additive manufacturing (AM) technology commonly employed formodeling, prototyping, and manufacturing applications, the major research issues have been to balance ability to produce aesthetically appealinglooking products with functionality. It is therefore critical to know the mechanical properties of these parts, which, is as expected different from their nominal values.A FDM manufactured part has an internal channel referred to as infill. This internal build pattern has different mechanical properties than the same shaped part without the internal channel. This paper aims to define the effect of specimen mesostructure on the monotonic tensile behavior of ABS parts manufactured by FDM. The experiment uses the uPrint SE 3D printer to produce samples from ABS thermoplastic. The samples are tested following a modified form of ASTM D638 standard for plastic. The printed pieces are tested to failure using an Instron testing machine, and a strain gage extensometer that measures the amount of elongation in the pieces until failure. These standardized pieces are compared to know values of traditionally manufactured materials. This test shows the strength loss of materials through the 3D printing process compared to traditional manufacturing methods. The experiment for plastics is designed around two key criteria, orientation of the pieces, and the percent of infill during the printing process. It was found that a value of maximum strength, of 3D printed ABS, was approximately 92% of accepted values for the material, with a certainty of 5%. The study also shows that the bonds between layers are only 79% as strong as an axil loading along the layers. <s> BIB019 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> Abstract The Additive Manufacturing (AM) technology initially was developed as a rapid prototyping tool for visualization and validation of designs. The recent development of AM technologies, such as Fused Deposition Modelling (FDM), is driving it from rapid prototyping to rapid manufacturing. However, building end-user functional parts using FDM proved to be a challenging task. The difficulty arises from the large number of processing parameters that affect the final part design such as: building direction, extrusion temperature, layer height, infill pattern and more. The processing parameters of FDM influence the quality of the parts and their functionality. In addition, a more systemic understanding is required to elaborate on the impact of the FDM processing parameters on the final part's mechanical properties, dimensional accuracy and building time. The presented paper provides an experimental study to investigate the independent effect of each processing parameter on the mechanical properties and dimensional accuracy repeatability of FDM parts. A total of 18 test specimen samples were printed using varying processing parameters. In order to investigate the repeatability and resulted tolerances, the dimensions of these specimens were measured and compared with a 3D CAD model. The presented work utilizes a tensile test per ASTM D638 standards to obtain the mechanical properties of each fabricated sample. In addition, the work provides a Finite Element Analysis (FEA) model for AM parts. The work suggested to simulate their behavior under mechanical loads for future investigation on the coupled effects of processing parameters. <s> BIB020 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> Abstract Fused deposition modelling is a rapidly growing additive manufacturing technology due to its ability to build functional parts having complex geometries. The mechanical properties of a built part depend on several process parameters. The aim of this study is to characterize the effect of build orientation, layer thickness and feed rate on the mechanical performance of PLA samples manufactured with a low cost 3D printer. Tensile and three-point bending tests are carried out to determine the mechanical response of the printed specimens. Due to the layer-by-layer process, 3D printed samples exhibit anisotropic behaviour. Upright orientation shows the lowest mechanical properties. On the other hand, on-edge and flat orientation show the highest strength and stiffness. From a layer thickness and feed rate point of view, it is observed that ductility decreases as layer thickness and feed rate increase. In addition, the mechanical properties increase as layer thickness increases and decrease as the feed rate increases for the upright orientation. However, the variations in mechanical properties with layer thickness and feed rate are of slight significance for on-edge and flat orientations, except in the particular case of low layer thickness. Finally, the practicality of the results is assessed by testing an evaluation structure. <s> BIB021 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> FDM Equipment <s> The control of process parameters to customize a part has been a value-added ability related to additive manufacturing (AM). In this paper, parametric optimization of fused deposition modeling (FDM) process is performed using Taguchi design of experiments (DOE). Two sets of experiments were conducted on an industrial case study from the aerospace industry to assess the impact of FDM process parameters: layer thickness, shells, infill pattern, and infill percentage, on the compressive strength of the case study. A generic methodology was also proposed. Analysis of variance (ANOVA) and signal-to-noise (S/N) ratio analysis were performed to evaluate the importance of experimental error, finding the optimal combination of process parameters for maximizing the compressive strength, and assessing the robustness of the design. The paper concluded with the display of results, discussion, and conclusions drawn. <s> BIB022
For research purposes, different research teams use different FDM machines. Stratasys was one of the first companies to develop the FDM process and FDM machine. The following is a list of commonly used FDM machines: Fortus FDM 400 mc machine (Stratasys, Eden Prairie, MN, USA) BIB011 BIB017 BIB016 , Fortus 360 mc machine (Stratasys, Eden Prairie, MN, USA)  , FDM 200 mc machine (Stratasys, Eden Prairie, MN, USA) BIB007 , FDM 1650 machine (Stratasys, Eden Prairie, MN, USA) BIB002 BIB001   , FDM Vantage machine (Stratasys, Eden Prairie, MN, USA) BIB008 BIB009 , Ultimaker 2 (Ultimaker, Amsterdam, Netherlands)    , MakerBot Replicator 2 (MakerBot, New York, NY, USA) BIB018 BIB013 , MEM-300 machine (Beijing Yinhua Laser Rapid Prototypes Making and Mould Technology Co., Ltd, Beijing, China) BIB012 , Uprint SE 3D printer (Stratasys, Eden Prairie, MN, USA) BIB019 , The FDM 3000 3D printer (Stratasys, Eden Prairie, MN, USA) BIB003  , Raise3D N2plus machine (Raise3D, Irvine, CA, USA)  , Makerbot Replicator 2X (MakerBot, New York, NY, USA) BIB022 BIB014 BIB020 , Julia 3D printer (Fracktal Works, Bangalore, India) BIB015 , FDM Maxum Machine (Stratasys, Eden Prairie, MN, USA) BIB004 , Prodigy Plus (Stratasys, Eden Prairie, MN, USA) BIB005 BIB006 , WitBox desktop 3D printer (BQ, Madrid, Spain) BIB021 , and HP Designjet 3D CQ656A (HP, Palo Alto, CA, USA) BIB010 . Please note that the list above is in no way exhaustive. There are also other do-it-yourself (DIY) FDM printers that are highly customizable. Each FDM machine has its advantages and disadvantages. Depending on the controllable process parameters that are offered by an FDM machine, and some other parameters that are difficult to control using a specific machine, each user may have a different view of the equipment. Thus, the advantages and disadvantages of each FDM machine are not the focus of this paper and are not discussed further in this paper.