Process Parameter Optimization of FDM Process Using DOE Methods

Authors- Mrs. U. Chaitanya Vardhini, Lella Lakshmi Satyanarayana, Guree Ashok, Paka Madhu Manohar, Pragada Jagadeeswarudu

Abstract-– Fused Deposition Modelling (FDM) is widely used for fabricating functional and prototype parts due to its cost-effectiveness and material versatility. However, optimizing process parameters is crucial to improving printing efficiency, material consumption, mechanical properties, and surface quality. This study employs Design of Experiments (DOE) methods to investigate the impact of infill pattern (concentric, quarter cubic, cubic subdivision), infill density (30%, 60%, 90%), and top & bottom closing layers (2, 4, 6 layers) on the overall performance of FDM-printed parts.A series of experiments were conducted using a statistical DOE approach, where the selected parameters were systematically varied to evaluate their effects on printing time, material consumption, surface roughness, and mechanical strength. The infill pattern plays a significant role in internal structure formation, influencing load distribution and energy absorption. The infill density directly impacts part strength and weight, while the top and bottom layers affect surface smoothness and structural integrity. The results indicate that cubic subdivision infill at higher densities (60%-90%) enhances mechanical strength but significantly increases printing time and material usage. The quarter cubic infill provides a balance between strength and weight reduction, making it suitable for lightweight applications. The concentric pattern demonstrated poor mechanical properties due to its lack of uniform load distribution. Additionally, increasing the number of top and bottom layers improved surface quality but also contributed to higher material consumption and extended print time.

DOI: /10.61463/ijset.vol.13.issue2.296