Investigating surfaces, geometry and degree of fusion of tracks printed using fused deposition modelling to optimise process parameters for polymeric materials at meso-scale

Purpose The current analysis was conducted to investigate the quality of surfaces and geometry of tracks printed using PolyMideTM CoPA, PolymaxTM PC and PolyMideTM PA6-CF materials through fused deposition modelling (FDM). This study also examined the degree of fusion of adjacent filaments (tracks) to approximate the optimal process parameters of the three materials. Design/methodology/approach Images of fused adjacent filaments were acquired using scanning electron microscopy (SEM), after which, they were analysed using Image J Software and Minitab Software to determine the optimal process parameters. Findings The optimal process parameters for PolyMideTM CoPA are 0.25 mm, 40 mm/s, −0.10 mm, 255°C and 0.50 mm for layer thickness, printing speed, hatch spacing, extrusion temperature and extrusion width, respectively. It was also concluded that the optimal process parameters for PolymaxTM PC are 0.30 mm, 40 mm/s, 0.00 mm, 260°C and 0.6 mm for layer thickness, printing speed, hatch spacing, extrusion temperature and extrusion width, respectively. Research limitations/implications It was difficult to separate tracks printed using PolyMideTM PA6-CF from the support structure, making it impossible to examine and determine their degree of fusion using SEM. Social implications The study provides more knowledge on FDM, which is one of the leading additive manufacturing technology for polymers. The information provided in this study helps in continued uptake of the technique, which can help create job opportunities, especially among the youth and young engineers. Originality/value This study proposes a new and a more accurate method for optimising process parameters of FDM at meso-scale level.