Optimization of fused deposition modeling process parameters using the Taguchi method to improve the tensile properties of 3D-printed polyether ether ketone

Abstract

The interesting mechanical properties of polyether ether ketone give the material a place among the foremost competitors when it comes to replacing metal. Fused deposition modeling has been recognized as an alternative method to process polyether ether ketone parts. In this study, the effect of different process parameters such as nozzle, bed, and radiant temperatures as well as printing speed and layer thickness on the tensile properties of three-dimensional printed polyether ether ketone was investigated. The optimization of the tensile properties of PEEK were studied by performing a reduced number of experiments, using the experimental design method based on the Taguchi approach which limits the number of experiments to 8 instead of 32. Results showed that a decent Young’s modulus was found by setting the nozzle temperature, print speed, and bed temperatures to their high levels and by setting the layer thickness and radiant temperature to their low level. Using these parameters, a Young’s modulus of 3.5 GPa was obtained, which represents 87.5% of the value indicated in the technical sheet. With these settings, we also found a tensile strength of 45.5 MPa, which corresponds to 46.4% of the value given by the studied polyether ether ketone material. A scanning electron microscopic investigation of the porosity and interlayer adhesion, confirmed that a higher bed temperature also tended to promote adhesion between layers.