Experimental Investigation and Optimization of FDM Process Parameters for Build Cost and Mechanical Properties Using I-Optimal Design

In this study the influence of fused deposition modeling (FDM) process parameters (layer thickness, air gap, raster angle, build orientation, road width and number of contours) on the processing cost and complex modulus of elasticity has been investigated using statistical design of experimental approach involving response surface methodology. The most influential parameters are obtained through analysis of variance (ANOVA) technique, which shows that layer thickness, air gap and number of contours have the largest impact on the part building cost and complex modulus of elasticity. The optimal process conditions to minimize the build cost without compromising the complex modulus of elasticity are also obtained.