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<p>The mechanical performance of fused filament fabricated polyethylene terephthalate glycol (PETG) parts is significantly influenced by process parameters. This presents study investigates combined effects of seven key parameters extrusion temperature (220–230&#xa0;°C), raster angle (0°–90°), printing speed (50–70&#xa0;mm/s), build orientation (flat, on-edge, upright), layer thickness (0.1–0.2&#xa0;mm), and infill density (60–100%) alongside three distinct infill patterns: rectilinear, honeycomb, and triangular. Total 81 unique sample configurations were fabricated and subjected to tensile, flexural, and impact testing. The results revealed build orientation and layer thickness as the most significant factors influencing mechanical performance. The on-edge build orientation achieved the highest tensile strength (40.7&#xa0;MPa), while a flat orientation with triangular infill and full density attained the highest flexural strength (69.4&#xa0;MPa). Honeycomb infill provided superior impact resistance (6.2&#xa0;kJ/m²). Higher extrusion temperatures enhanced inter-layer bonding and overall structural integrity. A Taguchi L27 orthogonal array and signal-to-noise ratio analysis identified significant main effects, while Response Surface Methodology (RSM) yielded predictive models with R² values exceeding 94%. ANOVA confirmed the statistical significance of primary factors and their interactions. Multi-objective optimization using the desirability function determined an optimal parameter set: 220&#xa0;°C extrusion temperature, 90° raster angle, 67&#xa0;mm/s printing speed, 0.1&#xa0;mm layer thickness, 67% infill density, rectilinear infill, and flat build orientation. This configuration achieved a desirability score of 1.000, with predicted tensile, flexural, and impact strengths of 41.9&#xa0;MPa, 70.0&#xa0;MPa, and 6.2&#xa0;kJ/m², respectively. These findings provide a robust, data-driven framework for optimizing fused filament fabricated PETG parts for drone applications.</p>

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Parametric optimization of 3D printing process parameter: an experimental cum statistical approach

  • 期刊论文

  • 发表日期：

    2026年3月11日

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  • Eknath Bayas,
  • Pramod Kumar

摘要

The mechanical performance of fused filament fabricated polyethylene terephthalate glycol (PETG) parts is significantly influenced by process parameters. This presents study investigates combined effects of seven key parameters extrusion temperature (220–230 °C), raster angle (0°–90°), printing speed (50–70 mm/s), build orientation (flat, on-edge, upright), layer thickness (0.1–0.2 mm), and infill density (60–100%) alongside three distinct infill patterns: rectilinear, honeycomb, and triangular. Total 81 unique sample configurations were fabricated and subjected to tensile, flexural, and impact testing. The results revealed build orientation and layer thickness as the most significant factors influencing mechanical performance. The on-edge build orientation achieved the highest tensile strength (40.7 MPa), while a flat orientation with triangular infill and full density attained the highest flexural strength (69.4 MPa). Honeycomb infill provided superior impact resistance (6.2 kJ/m²). Higher extrusion temperatures enhanced inter-layer bonding and overall structural integrity. A Taguchi L27 orthogonal array and signal-to-noise ratio analysis identified significant main effects, while Response Surface Methodology (RSM) yielded predictive models with R² values exceeding 94%. ANOVA confirmed the statistical significance of primary factors and their interactions. Multi-objective optimization using the desirability function determined an optimal parameter set: 220 °C extrusion temperature, 90° raster angle, 67 mm/s printing speed, 0.1 mm layer thickness, 67% infill density, rectilinear infill, and flat build orientation. This configuration achieved a desirability score of 1.000, with predicted tensile, flexural, and impact strengths of 41.9 MPa, 70.0 MPa, and 6.2 kJ/m², respectively. These findings provide a robust, data-driven framework for optimizing fused filament fabricated PETG parts for drone applications.