Fused filament fabrication is a material extrusion process, widely adopted additive manufacturing method, recognized for its versatility, simplicity, and cost effectiveness in producing customized composite polymer components across industries such as electronics, biomedical, automotive, and aerospace. This research addresses two technological performance characteristics (machine tool vibration Tv and surface roughness Ra) in 3D printing of acrylonitrile butadiene styrene/polycarbonate (ABS/PC) composite polymer, which hasn’t been addressed before. Additionally, this research explores the influence of machine tool vibration on surface morphology of printed parts aiming to optimize the 3D printing settings while balancing print quality and process stability. Four key process variables, including nozzle temperature, nozzle speed, infill density and layer thickness, are taken into consideration during the trials involving the thirty trials as per central composite design of experiments. The statistical method including analysis of variance and response surface methodology (RSM) in associated with desirability function approach (DFA) has been utilized for assessment, predictive modelling and multi-response optimization of performance characteristics (Ra, Tv) in 3D printing. Results revealed that nozzle speed (36.08%) and infill density (10.26%) predominantly affect surface roughness in ABS/PC 3D printing, and reducing these parameters lowers Ra, while higher nozzle temperature improves surface finish. Machine tool vibration is mainly governed by infill density (49.80%), nozzle speed (17.14%), and layer thickness (2.01%); higher infill density and nozzle speed increase vibration, and thinner layers further intensify the Tv. Increased nozzle speeds cause mechanical vibrations in the print head and build platform, causing material deviations, layer distortion, and poor surface finish. The developed RSM models accurately predict 3D printing performance, supported by low p-value (<0.05), high R2 value, and significant AD-test value. Using DFA, the optimal values for machine tool vibration and surface roughness were obtained as 0.104 m/s2 and 1.309 µm, respectively, achieved under nozzle speed of 30 mm/s, infill density of 40%, layer thickness of 0.05 mm, and nozzle temperature of 220°C. The proposed methodology offers an effective framework for improving 3D printing, enabling predictive modelling, process optimization with coupled effects of key process variables across a wide range of composite polymers.
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