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<p>The additive manufacturing (AM) process enables the rapid realization of complex shapes at a reduced manufacturing time, but with compromised quality when it comes to surface finish. The additively manufactured parts exhibit stair-case effects due to planar layers. To overcome this, researchers proposed deploying conformal or non-planar layers with minimal surface roughness. However, researchers rarely performed process parameter optimization studies for non-planar AM processes. Hence, to address this research gap, an exclusive Taguchi-based design of experiments is deployed to optimize process parameters in the material extrusion process, aiming to achieve an enhanced surface finish for non-planar printed parts. In this research, a fused deposition modelling (FDM) machine is customized with a long-tapered airbrush nozzle to avoid collisions and print non-planar layers. The results from the analysis of variance demonstrate the importance of process parameters in non-planar layer printing, as well as minor adjustments that yield superior-quality parts. The extrusion multiplier exhibits the greatest statistical significance at 84.30%, consequently confirming it as the primary contributor to the curved layer FDM (CLFDM) process. Conversely, layer thickness contributes the least at 3.10%. The major finding is that crucial process parameters like the extrusion multiplier (flow rate) significantly impact the CLFDM process, ensuring a high-quality surface finish.</p>

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Optimization of curved layer fused deposition modeling process parameters to enhance surface finish

  • 期刊论文

  • 发表日期：

    2025年6月14日

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  • Srikanth Mukka,
  • Arun Tom Mathew,
  • Ranjeet Kumar Bhagchandani

摘要

The additive manufacturing (AM) process enables the rapid realization of complex shapes at a reduced manufacturing time, but with compromised quality when it comes to surface finish. The additively manufactured parts exhibit stair-case effects due to planar layers. To overcome this, researchers proposed deploying conformal or non-planar layers with minimal surface roughness. However, researchers rarely performed process parameter optimization studies for non-planar AM processes. Hence, to address this research gap, an exclusive Taguchi-based design of experiments is deployed to optimize process parameters in the material extrusion process, aiming to achieve an enhanced surface finish for non-planar printed parts. In this research, a fused deposition modelling (FDM) machine is customized with a long-tapered airbrush nozzle to avoid collisions and print non-planar layers. The results from the analysis of variance demonstrate the importance of process parameters in non-planar layer printing, as well as minor adjustments that yield superior-quality parts. The extrusion multiplier exhibits the greatest statistical significance at 84.30%, consequently confirming it as the primary contributor to the curved layer FDM (CLFDM) process. Conversely, layer thickness contributes the least at 3.10%. The major finding is that crucial process parameters like the extrusion multiplier (flow rate) significantly impact the CLFDM process, ensuring a high-quality surface finish.