Process parameter optimisation for dimensional accuracy of vacuum-assisted printed samples using response surface methodology

Hazman, Muhammad Hazim Iskandar (2024) Process parameter optimisation for dimensional accuracy of vacuum-assisted printed samples using response surface methodology. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

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Abstract

Fused Deposition Modelling (FDM) is a widely used additive manufacturing (AM) technique renowned for its versatility and cost-effectiveness in producing complex prototypes and parts. Despite these advantages, FDM faces challenges such as limited mechanical properties, surface quality issues, and low dimensional accuracy, which hinder its broader adoption. Integrating a vacuum system can significantly improve the printed samples' dimensional accuracy. The goal of this paper is to enhance the dimensional accuracy of FDM thermoplastic Acrylonitrile Butadiene Styrene (ABS) and Polylactic Acid (PLA) samples by optimizing two process parameters: Infill Density (20%, 55%, 80%) and Printing Pressure (101.3 kPa atmospheric pressure and 20 kPa vacuum pressure). Upon completion of the printing process, the samples' dimensions were carefully assessed using a Coordinate Measuring Machine (CMM), measuring the hole diameter, corner diameter, thickness, width, length, and perpendicularity. The results indicated that while the material has yet to reach 100% of the desired geometry, the vacuum-printed samples for each material demonstrated improved dimensional accuracy compared to those printed at atmospheric pressure. The response surface methodology (RSM) was employed to relate the process parameters with dimensional accuracy and to evaluate the optimal process parameters. The results showed that the optimal process parameters for ABS are 55% infill density and 20 kPa vacuum pressure, while for PLA, they are 80% infill density and 20 kPa vacuum pressure to achieve good dimensional accuracy.

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