Ironing Process Optimization for Enhanced Properties in Material Extrusion technology using Box-Behnken Design

Abstract

Abstract Material Extrusion (MEX) technology, a prominent method in the field of additive manufacturing (AM), has witnessed significant growth in recent years. The continuous quest for enhanced material properties and refined surface quality has led to the exploration of post-processing techniques. In this study, we delve into the ironing process as a vital processing step, focusing on the optimization of its parameters through the application of Design of Experiments (DoE), specifically the Box-Behnken Design (BBD). The investigation reveals the profound impact of ironing on material properties and surface quality. Through a systematic exploration of ironing process parameters, we identify optimal conditions that lead to substantial improvements in Ultimate Tensile Strength (UTS), Compressive Strength (CS), Flexural Strength (FS), Impact Strength (IS), and surface roughness (Ra). The introduction of ironing minimizes voids, enhances layer bonding, and reduces surface irregularities, resulting in components that not only exhibit exceptional mechanical performance but also possess refined aesthetics. This research sheds light on the transformative potential of precision experimentation, post-processing techniques, and statistical methodologies in advancing Material Extrusion technology. The findings offer practical implications for industries requiring high-performance components with structural integrity and aesthetic appeal.