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<p>Fused Deposition Modeling (FDM) is a prevalent additive manufacturing technology, yet achieving an optimal balance between mechanical performance and material efficiency remains challenging due to the multi-parameter nature of the process and the anisotropy of layer-wise deposition. This study addresses a three-objective formulation for PLA-FDM by jointly maximizing maximum stress and elongation at break while minimizing total material consumption (deposited mass), where the material-consumption response includes the printed part and its support structures. A 40-run D-optimal design was employed to study six key parameters (layer thickness, infill density, infill pattern, build orientation, number of shells, and extrusion temperature). Tensile tests were conducted on ASTM D638 specimens, and second-order regression surrogates were developed and statistically assessed (Type-II ANOVA and residual diagnostics). On the full dataset (<i>n</i> = 40), the models achieved R² = 0.888 (RMSE = 4.51&#xa0;MPa) for MaxStress, R² = 0.708 (RMSE = 0.237%) for Elongation, and R² = 0.879 (RMSE = 2.98&#xa0;g) for Mass. ANOVA identified build orientation as the dominant factor for tensile behavior and mass, while infill density and shell count were highly significant drivers of both strength and material usage. A Pareto-based multi-objective analysis was then performed using the validated surrogates to provide reproducible trade-offs between strength, ductility, and material efficiency, enabling application-driven parameter selection within the explored domain.</p>

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Multi-objective optimization of mechanical properties and material efficiency in FDM 3D printing of polylactic acid (PLA)

  • 期刊论文

  • 发表日期：

    2026年3月14日

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  • Niama Arreda,
  • Hamza Isksioui,
  • Mohamed Bounouib,
  • Abderrahim Oudra,
  • Haj El Moussami

摘要

Fused Deposition Modeling (FDM) is a prevalent additive manufacturing technology, yet achieving an optimal balance between mechanical performance and material efficiency remains challenging due to the multi-parameter nature of the process and the anisotropy of layer-wise deposition. This study addresses a three-objective formulation for PLA-FDM by jointly maximizing maximum stress and elongation at break while minimizing total material consumption (deposited mass), where the material-consumption response includes the printed part and its support structures. A 40-run D-optimal design was employed to study six key parameters (layer thickness, infill density, infill pattern, build orientation, number of shells, and extrusion temperature). Tensile tests were conducted on ASTM D638 specimens, and second-order regression surrogates were developed and statistically assessed (Type-II ANOVA and residual diagnostics). On the full dataset (n = 40), the models achieved R² = 0.888 (RMSE = 4.51 MPa) for MaxStress, R² = 0.708 (RMSE = 0.237%) for Elongation, and R² = 0.879 (RMSE = 2.98 g) for Mass. ANOVA identified build orientation as the dominant factor for tensile behavior and mass, while infill density and shell count were highly significant drivers of both strength and material usage. A Pareto-based multi-objective analysis was then performed using the validated surrogates to provide reproducible trade-offs between strength, ductility, and material efficiency, enabling application-driven parameter selection within the explored domain.