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<p>Polymeric products, designed to withstand different environmental conditions along with substantial mechanical loading, are nowadays produced through the fused filament fabrication (FFF) process and intended for various outdoor applications fields. However, the strength and durability of these products can be substantially compromised when exposed to different outdoor environmental conditions. The aim of this investigation is to examine the influence of FFF process parameters, such as extrusion temperature, printing speed, and layer thickness, in both X- and Z-build orientations, on the mechanical responses (MR) of acrylonitrile styrene acrylate (ASA) polymer components. Moreover, the investigation focuses on multi-response optimization using a combination of grey relational analysis (GRA) and the technique for order preference by similarity to ideal solution (TOPSIS) for maximizing the tensile and flexural properties of the ASA polymer. The results obtained from the combined GRA-TOPSIS approach revealed that the optimal combination for maximizing MR (tensile strength, tensile modulus, flexural strength, and flexural modulus) was achieved at ET-245&#xa0;°C, PS-50&#xa0;mm/s, and LT-0.14&#xa0;mm in the X-build orientation. An ANOVA analysis study showed that build orientation (81.57%) was the most influential parameter, followed by extrusion temperature (4.36%) and extrusion temperature-layer thickness interaction (6.47%), significantly affecting the overall strength of FFF-fabricated ASA components. Confirmation tests conducted at optimal settings validated the predicted values, showing a strong agreement with experimental results and an 86.5% improvement in performance. These optimized process parameters can be utilized for the development of high-performance FFF-fabricated ASA components for outdoor applications, such as automotive, aerospace, and marine industries.</p> Graphical Abstract <p></p>

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Optimization of FFF parameters for mechanical performance enhancement of ASA polymer in outdoor applications

  • 期刊论文

  • 发表日期：

    2025年3月24日

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  • Sagar Kailas Gawali,
  • Prashant Kumar Jain

摘要

Polymeric products, designed to withstand different environmental conditions along with substantial mechanical loading, are nowadays produced through the fused filament fabrication (FFF) process and intended for various outdoor applications fields. However, the strength and durability of these products can be substantially compromised when exposed to different outdoor environmental conditions. The aim of this investigation is to examine the influence of FFF process parameters, such as extrusion temperature, printing speed, and layer thickness, in both X- and Z-build orientations, on the mechanical responses (MR) of acrylonitrile styrene acrylate (ASA) polymer components. Moreover, the investigation focuses on multi-response optimization using a combination of grey relational analysis (GRA) and the technique for order preference by similarity to ideal solution (TOPSIS) for maximizing the tensile and flexural properties of the ASA polymer. The results obtained from the combined GRA-TOPSIS approach revealed that the optimal combination for maximizing MR (tensile strength, tensile modulus, flexural strength, and flexural modulus) was achieved at ET-245 °C, PS-50 mm/s, and LT-0.14 mm in the X-build orientation. An ANOVA analysis study showed that build orientation (81.57%) was the most influential parameter, followed by extrusion temperature (4.36%) and extrusion temperature-layer thickness interaction (6.47%), significantly affecting the overall strength of FFF-fabricated ASA components. Confirmation tests conducted at optimal settings validated the predicted values, showing a strong agreement with experimental results and an 86.5% improvement in performance. These optimized process parameters can be utilized for the development of high-performance FFF-fabricated ASA components for outdoor applications, such as automotive, aerospace, and marine industries.

Graphical Abstract