Evaluating Impact of Different Parameters in Additive Manufacturing for Complex Situations

Additive manufacturing (AM) has emerged as an effective method for fabricating parts with internal complex features. However, optimizing process parameters to achieve desired mechanical properties for such complex geometries remains a challenge. This research aims to systematically evaluate the influence of AM process parameters on the tensile strength of PLA plus specimens containing a rectangular channel integrated inside the gauge section. A Taguchi L9 orthogonal design of experiments was formulated with four control factors - printing temperature, layer height, wall line count and infill percentage. Tensile testing specimen of standard ASTM D638-Type I containing a rectangular channel of 1.5x5x50mm was printed on an FDM machine. Tensile testing determined the ultimate tensile strength and percentage of elongation as the response. Signal- to-noise ratio analysis revealed optimized levels as 210°C, 0.20mm, 3 wall lines and 100% infill. Tensile testing of specimens printed at these conditions yielded average UTS of 34.58 MPa. Adopting Taguchi methodology, this study aims to improve understanding of interplay between key AM parameters and mechanical properties for PLA plus specimens with complex internal geometry. Optimized settings aid quality fabrication of functionally graded parts with intricate designs using this sustainable FDM material. Statistical design of experiments serves as an efficient evaluation approach.