Optimization of fused filament fabrication system by response surface method

Fused filament fabrication (FFF) is a 3D printing or additive manufacturing method used for rapid prototyping and manufacturing. The characterization and optimization of process parameters in FFF is of critical importance because the quality of the specimens produced by this method substantially depends on the appropriate setting of various significant factors. In this study, the FFF printing process using acrylonitrile butadiene styrene (ABS) as the filament material was investigated for the optimization of significant factors in the process. Three potential factors, namely nozzle temperature, bed temperature, and printing speed, were included in this study as the inputs, while surface roughness of the specimens was considered as the output. Roughness measurements were made on the flat surfaces at the top and bottom of the specimens. As the ranges for optimal factor settings were recommended by the manufacturer, the Box-Behnken design, which is a response surface method (RSM), was utilized in this study. In each treatment, two replicas of the test specimens were used for the confirmation test. The results of the statistical analyses indicated that the bed temperature and the printing speed had a significant impact on the surface roughness. Another finding was that there was a non-linear relationship between the bed temperature and the surface roughness. The optimal settings for the factors arrived at in this study can serve as guidelines for the practitioners to achieve the highest performance when they use FFF with ABS filaments.