This study optimizes fused filament fabrication (FFF) parameters to enhance the tribological performance of Kevlar fibre–reinforced polylactic acid (PLA) nanocomposites. Filaments containing 0–10 wt-% Kevlar were produced by twin-screw extrusion and characterized for mechanical and thermal behavior. A 30-run central composite design evaluated the effects of layer height (0.1–0.3 mm), build orientation (0–90°), wall width (0.2–0.6 mm), and Kevlar content on specific wear rate. Statistical analysis identified layer height as the dominant factor (F = 2336.47), contributing 83.3% of the total variation. Predictive modeling using ANN and adaptive neuro-fuzzy inference systems ANFIS demonstrated superior accuracy for ANFIS (R 2 = 0.9985 training, 0.9912 validation, 0.9647 testing). The optimized parameter set yielded a minimum wear rate of 0.0187 mm 3 /s with 1.06% prediction error, validated using functional spur gear testing.
Balu et al. (Fri,) studied this question.