Single and Multi-objective Optimization of Processing Parameters for Fused Deposition Modeling in 3D Printing Technology

Abstract

This paper presents practice and application of Design of Experiment techniques and Genetic Algorithm in single and multi-objective optimization with low cost, robustness, and high effectiveness through 3D printing case studies. 3D printing brings many benefits for engineering design, product development, and production process. However, it faces many challenges related to parameters control. The wrong parameter setup can result in excessive time, high production cost, waste material, and low-quality printing. This study is conducted to optimize the parameter sets for 3D Fused Deposition Modelling (FDM) products. The parameter sets, i.e., layer height, infill percentage, printing temperature, printing speed with different levels are experimented and analyzed to build mathematic models. The objectives are to describe the relationship between the inputs (parameter values) and the outputs (printing quality in term of weight, printing time and tensile strength of products). Single-objective and multi-objective models according to user’s desire are constructed and studied to identify the optimal set, optimal trade-off set of parameters. Besides, an integrated method of response surface methodology and Genetic algorithm to deal with multi-objective optimization is discussed in the paper. 3D printer, testing machines, and quality tools are used for doing experiments, measurement and collecting data. Minitab and Matlab software aid for analysis and decision-making. Proposed solutions for handling multi-objective optimization through 3D Fused Deposition Modelling product printing case study are practical and can extend for other case studies.