Optimization of Fused Deposition Method (FDM) 3D Printer Parameters: An Experimental and Data-Driven Investigation on Tensile Strength and Surface Roughness with Polyethylene Terephthalate Glycol (PETG) Filament


Kaptan A.

12. International Conference on Materials Science and Nanotechnology for Next Generation, Sivas, Türkiye, 10 - 12 Eylül 2025, ss.1-10, (Tam Metin Bildiri)

  • Yayın Türü: Bildiri / Tam Metin Bildiri
  • Basıldığı Şehir: Sivas
  • Basıldığı Ülke: Türkiye
  • Sayfa Sayıları: ss.1-10
  • Sivas Cumhuriyet Üniversitesi Adresli: Evet

Özet

This study systematically demonstrates the effects of critical process parameters on mechanical performance (tensile strength, σ) and surface finish (Ra) during FDM 3D printing using PETG filament. A Taguchi L27 orthogonal array was used for experimental planning, and three levels of layer thickness (0.12–0.28 mm), infill ratio (20–80%), printing speed (40–80 mm/s), nozzle temperature (220–250 °C), and scanning angle (0°–90°) were investigated. Samples were produced on a FlashForge Adventurer 5M Pro printer with a 0.4 mm nozzle, subjected to tensile tests according to ASTM D638 Type V, and Ra measurements were evaluated using the ISO 4287 (cut-off 0.8 mm) approach. The multi-criteria objective (σ↑, Ra↓) was combined with the desirability approach, and a single optimum setting was reported. OLS-based impact assessment (adj. R²=0.990, Ra model adj. R²=0.974) was used for non-categorical parametric analysis, and Random Forest (5-fold cross-validation) was used for estimation (R²≈0.47 for σ; R²≈0.32 for Ra). The findings show that the combination of thinner layer, lower speed, nozzle temperature around 245 °C, and 0° scan angle increases σ while decreasing Ra; the fill rate has a positive but limited effect on σ, with a secondary effect on Ra. The recommended optimum parameters were determined as follows: 0.12 mm layer thickness, 80% fill rate, printing speed of 50–60 mm/s, nozzle temperature of 245 °C, 0° scan angle, table temperature of 85 °C, and 30% fan speed ratio.