Face Centered Central Composite Design to Optimize The Material Extrusion Process

Authors- Mr. A. Yeswanth, Penke Jagan Mohan, Pichika Balaji Sai Manikanta, Badugu Likhilbabu, Kalvakolanu Raj Kumar

Abstract-Material Extrusion (MEX), commonly used in Fused Deposition Modeling (FDM), requires precise process optimization to balance printing efficiency, surface quality, and material usage. This study employs the Face-Centered Central Composite Design (FCCCD), a statistical Design of Experiments (DOE) method, to optimize shell thickness, layer width (line width), and travel speed, aiming to minimize printing time while enhancing surface finish. The FCCCD approach allows a systematic evaluation of parameter interactions by generating a response surface model. Shell thickness affects part rigidity and material consumption, layer width influences bonding strength and print resolution, while travel speed impacts deposition accuracy and total fabrication time. Experiments were conducted using Fusion 360’s process simulation tools, followed by statistical analysis to identify optimal settings. Results indicate that optimized shell thickness and line width contribute to a better surface finish, while increasing travel speed reduces printing time but can affect deposition accuracy. The response surface methodology (RSM) derived from FCCCD enables efficient parameter tuning, ensuring a balance between production speed and part quality. This study demonstrates that FCCCD is a reliable approach for optimizing MEX process parameters, leading to improved efficiency and reduced waste. The findings provide a scientific foundation for enhancing FDM-based manufacturing, making it more cost-effective and sustainable.

DOI: /10.61463/ijset.vol.13.issue2.250