Effect of Printing Parameters on Dimensional Error, Surface Roughness and Porosity of FFF Printed Parts with Grid Structure

Abstract

Extrusion printing processes allow for manufacturing complex shapes in a relatively cheap way with low-cost machines. The present study analyzes the effect of printing parameters on dimensional error, roughness, and porosity of printed PLA parts obtained with grid structure. Parts are obtained by means of the fused filament fabrication (FFF) process. Four variables are chosen: Layer height, temperature, speed, and flow rate. A two-level full factorial design with a central point is used to define the experimental tests. Dimensional error and porosity are measured with a profile projector, while roughness is measured with a contact roughness meter. Mathematical regression models are found for each response, and multi-objective optimization is carried out by means of the desirability function. Dimensional error and roughness depend mainly on layer height and flow rate, while porosity depends on layer height and printing speed. Multi-objective optimization shows that recommended values for the variables are layer height 0.05 mm, temperature 195 ºC, speed 50 mm/min, and flow rate 0.93, when dimensional error and roughness are to be minimized, and porosity requires a target value of 60%. The present study will help to select appropriate printing parameters for printing porous structures such as those found in prostheses, by means of extrusion processes.