Design and optimization of the process parameters for fusion deposition modelling by experimental and finite element approach

Fused Deposition Modelling (FDM) is a rapidly evolving technology since the last couple of years. This method is also used for rapid prototyping, which uses layer on top of layer deposition of the material using hot extruders to build a given 3D model. 3D printing technology basically a tool-less process designed specifically to avoid assembly requirements with intricate geometry and complex features created at no extra cost and at the same time it is an energy-efficient technology that can provide environmental efficiencies in terms of both the manufacturing process and material utilization. This research primarily focuses on analyzing the critical process parameters and its influence on the properties of the components made out of FDM process. The FDM specimens are fabricated by using four factors (parameters) at three levels, and the factors are layer thickness, travel speed of the extruder, infill ratio, and infill density. The experiments are designed based on Taguchi L-9 orthogonal array. Total three responses are considered and they are tensile strength compressive strength and flexural strength. Taguchi analysis has done to optimize the factors and its levels. Finite element analysis has also done and compared with the experimental results.