Optimising the fused filament fabrication process employing the experimental design approach: An expository paradigm under cold weather conditions and lightweight specimens
Among all 3D printing technologies, open chamber filament material extrusion (ME) is a rapidly growing technique to many extents. Despite the benefits, various topics concerning the robustness and quality of the 3D−printed parts remain vague, especially when operating in cold weather conditions. An...
Saved in:
| Main Authors: | , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2025-04-01
|
| Series: | Next Materials |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2949822824002843 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1850178150611288064 |
|---|---|
| author | Praveen Kumar Rajneesh Patel Indraj Singh Sanat Agrawal John D. Kechagias |
| author_facet | Praveen Kumar Rajneesh Patel Indraj Singh Sanat Agrawal John D. Kechagias |
| author_sort | Praveen Kumar |
| collection | DOAJ |
| description | Among all 3D printing technologies, open chamber filament material extrusion (ME) is a rapidly growing technique to many extents. Despite the benefits, various topics concerning the robustness and quality of the 3D−printed parts remain vague, especially when operating in cold weather conditions. An engineering polymer, acrylonitrile−butadiene−styrene (ABS), has been utilised due to its immense applicability in automotive industries and its low cost. However, different process parameters, their correlation, and various environmental factors affect the enactment of filament ME components. In the current research, the effect of ME 3D printing process parameters such as layer thickness, extrusion temperature, and raster angle were selected after preliminary testing and optimised for surface roughness and tensile strength for ABS under cold weather conditions for 60 % infill rate lightweight specimens by using response surface methodology (RSM). It has been observed that mean surface roughness decreases as layer thickness and raster angle decrease and extrusion temperature increases (close to 4.24 µm). Maximum tensile strength is also reported at minimum layer thickness and higher extrusion temperature. Furthermore, the tensile fractured surface morphology has revealed the close packing of layers at 0º/90º raster angle, 240 ºC extrusion temperature, and 0.1 mm layer thickness (about 31 MPa). The study outcomes can assist industries operating in cold weather conditions in their pursuit of achieving high mechanical performance and superior surface finish. Beyond optimizing print quality, the study highlights the need for developing more resilient printing methodologies that can adapt to environmental fluctuations. Furthermore, this research offers a valuable contribution to sustainability efforts, as achieving high performance with lightweight materials can reduce material waste and energy consumption. |
| format | Article |
| id | doaj-art-70edff34880a4594b39c772a1bface91 |
| institution | OA Journals |
| issn | 2949-8228 |
| language | English |
| publishDate | 2025-04-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Next Materials |
| spelling | doaj-art-70edff34880a4594b39c772a1bface912025-08-20T02:18:48ZengElsevierNext Materials2949-82282025-04-01710038710.1016/j.nxmate.2024.100387Optimising the fused filament fabrication process employing the experimental design approach: An expository paradigm under cold weather conditions and lightweight specimensPraveen Kumar0Rajneesh Patel1Indraj Singh2Sanat Agrawal3John D. Kechagias4Sant Longowal Institute of Engineering and Technology, Longowal, Punjab 148106, India; Corresponding authors.Sant Longowal Institute of Engineering and Technology, Longowal, Punjab 148106, IndiaSant Longowal Institute of Engineering and Technology, Longowal, Punjab 148106, IndiaNational Institute of Technology, Srinagar, Uttrakhand 246174, IndiaUniversity of Thessaly, Karditsa 43100, Greece; Corresponding authors.Among all 3D printing technologies, open chamber filament material extrusion (ME) is a rapidly growing technique to many extents. Despite the benefits, various topics concerning the robustness and quality of the 3D−printed parts remain vague, especially when operating in cold weather conditions. An engineering polymer, acrylonitrile−butadiene−styrene (ABS), has been utilised due to its immense applicability in automotive industries and its low cost. However, different process parameters, their correlation, and various environmental factors affect the enactment of filament ME components. In the current research, the effect of ME 3D printing process parameters such as layer thickness, extrusion temperature, and raster angle were selected after preliminary testing and optimised for surface roughness and tensile strength for ABS under cold weather conditions for 60 % infill rate lightweight specimens by using response surface methodology (RSM). It has been observed that mean surface roughness decreases as layer thickness and raster angle decrease and extrusion temperature increases (close to 4.24 µm). Maximum tensile strength is also reported at minimum layer thickness and higher extrusion temperature. Furthermore, the tensile fractured surface morphology has revealed the close packing of layers at 0º/90º raster angle, 240 ºC extrusion temperature, and 0.1 mm layer thickness (about 31 MPa). The study outcomes can assist industries operating in cold weather conditions in their pursuit of achieving high mechanical performance and superior surface finish. Beyond optimizing print quality, the study highlights the need for developing more resilient printing methodologies that can adapt to environmental fluctuations. Furthermore, this research offers a valuable contribution to sustainability efforts, as achieving high performance with lightweight materials can reduce material waste and energy consumption.http://www.sciencedirect.com/science/article/pii/S2949822824002843Filament material extrusionABS3D−printingStrengthRoughnessFace−centered central composite design |
| spellingShingle | Praveen Kumar Rajneesh Patel Indraj Singh Sanat Agrawal John D. Kechagias Optimising the fused filament fabrication process employing the experimental design approach: An expository paradigm under cold weather conditions and lightweight specimens Next Materials Filament material extrusion ABS 3D−printing Strength Roughness Face−centered central composite design |
| title | Optimising the fused filament fabrication process employing the experimental design approach: An expository paradigm under cold weather conditions and lightweight specimens |
| title_full | Optimising the fused filament fabrication process employing the experimental design approach: An expository paradigm under cold weather conditions and lightweight specimens |
| title_fullStr | Optimising the fused filament fabrication process employing the experimental design approach: An expository paradigm under cold weather conditions and lightweight specimens |
| title_full_unstemmed | Optimising the fused filament fabrication process employing the experimental design approach: An expository paradigm under cold weather conditions and lightweight specimens |
| title_short | Optimising the fused filament fabrication process employing the experimental design approach: An expository paradigm under cold weather conditions and lightweight specimens |
| title_sort | optimising the fused filament fabrication process employing the experimental design approach an expository paradigm under cold weather conditions and lightweight specimens |
| topic | Filament material extrusion ABS 3D−printing Strength Roughness Face−centered central composite design |
| url | http://www.sciencedirect.com/science/article/pii/S2949822824002843 |
| work_keys_str_mv | AT praveenkumar optimisingthefusedfilamentfabricationprocessemployingtheexperimentaldesignapproachanexpositoryparadigmundercoldweatherconditionsandlightweightspecimens AT rajneeshpatel optimisingthefusedfilamentfabricationprocessemployingtheexperimentaldesignapproachanexpositoryparadigmundercoldweatherconditionsandlightweightspecimens AT indrajsingh optimisingthefusedfilamentfabricationprocessemployingtheexperimentaldesignapproachanexpositoryparadigmundercoldweatherconditionsandlightweightspecimens AT sanatagrawal optimisingthefusedfilamentfabricationprocessemployingtheexperimentaldesignapproachanexpositoryparadigmundercoldweatherconditionsandlightweightspecimens AT johndkechagias optimisingthefusedfilamentfabricationprocessemployingtheexperimentaldesignapproachanexpositoryparadigmundercoldweatherconditionsandlightweightspecimens |