Estimation of the Effect of Process Parameters on Build Time and Model Material Volume for FDM Process Optimization by Response Surface Methodology and Grey Relational Analysis

Abstract

In this study, a hybrid optimization approach is proposed for build time and model material volume in Fused Deposition Modeling (FDM) process on a FDM Maxum Modeler. A combination of response surface methodology (RSM) and grey relational analysis (GRA) is proposed and applied to optimize process parameters of FDM process. The significant input parameters such as contour width, air gap, raster angle, and spatial orientation are considered, and build time and model material have been taken as responses for this study. Thirty experiments were conducted on acrylonitrile butadiene styrene (ABS) P400 for conical primitives using full factorial central composite design. The optimum process parameter conditions were obtained from grey relational grade. The results obtained provide useful information of the method to control responses and ensure minimal build time and model material volume for prototy** requirements. The assessment outcome provided a scientific reference to obtain minimal values of build time and model material volume utilized, and it was found out that these correspond to a contour width of 0.654 mm, air gap of 0.0254 mm, raster angle of 0°, and orientation of 0°.