On the optimized fused filament fabrication of polylactic acid using multiresponse central composite design and desirability function algorithm

Abstract

Efficient optimization of polymeric materials in fused filament fabrication 3D printing (FFF 3DP) is crucial for productivity, cost reduction, resource conservation, consistency, and enhanced part performance. This study employed a multiresponse central composite design of experiments (CCD-DOE) with the desirability function algorithm (DFA) to optimize printing settings on polylactic acid (PLA) using a commercial FFF 3D printer. The goal was to identify optimal parameters for faster build time and reduced material usage in PLA part fabrication. The fabrication process involved computer-aided design and modeling of standard PLA dogbone specimens, meeting ASTM-D638 Type 1 tensile test standards. These specimens were then 3D printed using Ultimaker Green RAL 6018 PLA filament and a 2+ model printer set at varying print parameters. Reduced second-order polynomial models for printing time and PLA weight were generated using stepwise regression, eliminating noninfluential parameters. The models revealed that higher layer thickness, increased print speed, and lower infill density resulted in faster printing times, while lower infill density and higher layer thickness led to lighter PLA prints. DFA analysis determined the optimal settings as a layer thickness of 0.26–0.30 mm and an infill density of 35% for minimizing printing time and PLA weight. The stress–strain curves displayed characteristic high-strength, brittle behavior under tension, while tensile testing of optimized PLA parts revealed increased strength with low strain at the break when layers were aligned parallel to the applied force. These findings advance additive manufacturing and provide practical guidelines for high-quality 3D-printed PLA components. Optimizing FFF 3DP parameters enables efficient production with reduced time and material usage, enhancing cost-effectiveness and the fabrication of high-performance 3D printed products.