Parametric optimization of 3D printing process hybridized with laser-polished PETG polymer

The potential of Fused Filament Fabrication (FFF) technology to produce very complex geometrics has a profound impact on the physical world. Practitioners in the industry are developing predictive methods for assessing key parameters and responses of engineering materials. Enterprises are trying to solve problems such as Flexural Strength (FS), Average Surface Roughness (Ra), Tensile Strength (TS), sustainability including energy efficacy, and time management problems. This study's objective is divided into two main parts. The First part includes the parametric investigations of Polyethylene Terephthalate Glycol (PETG) polymer to optimize the mechanical properties, Ra, and sustainability, including Print Time (T) and Printer Energy consumption (E) of samples using the FFF technique. In second part, samples were printed at optimized parametric values and further post-processed to enhance the responses such as TS, FS, Ra, and Laser Scan Time (Tl) using CO2 laser polishing treatment. FFF with PETG, a biodegradable material, is commonly used in various fields, despite the traditionally significant surface roughness of FFF products. In pre-processing, by optimizing 3D printed parameters, FS of 69.9 MPa, lowest Ra of 6.8 μm, TS of 45.1 MPa, lowest T of 53 min and E of 0.20 kWh were attained. In post-processing, the Ra decreased by more than 58.38% due to laser polishing (6.8 μm–2.81 μm). The TS increased by 8.89%, from 45.1 MPa to 49.11 MPa. SEM investigation revealed that the gaps in the material lowered the FS by 5.09%, from 69.9 MPa to 66.34 MPa and Tl for 0.22 min. The fracture morphologies were studied as a means of learning more about the reinforcing process in the future. These outcomes prove that laser scanning can improve and alter the surface of an FFF product.