Optimization of FDM parameters for improving part quality, productivity and sustainability of the process using Taguchi methodology and desirability approach

Additive manufacturing (AM) has gained attention due to its capacity to produce complex parts. Fused deposition modeling (FDM) is a branch of AM that has great potential. However, it is important to understand how process parameters affect part quality and operation’s productivity. The present paper outlines an experimental study that aimed to optimize three parameters: processing time, the energy consumption of the 3D printer, and dimensional accuracy of parts manufactured by the FDM process, using ASA as the model material. The Taguchi methodology was employed to study the effect of five key parameters (layer thickness, filling pattern, orientation angle, printing plane, and position of the piece on the printing table’s surface) on the variables. The desirability method was considered for defining a set of printing parameters that allowed the optimization of all the variables at the same time. The printing plane was the most significant factor for reducing processing time; the same trend was observed for energy consumption. In the case of dimensional accuracy, the width was mainly influenced by the filling pattern. For length, layer thickness was the dominant factor. Finally, the printing plane was the factor with the greatest influence over the part thickness. A desirability analysis allowed finding out the set of parameters that provided the best trade-off among the variables.