Analyzing the effects of printing parameters to minimize the dimensional deviation of polylactic acid parts by applying three different decision-making approaches

Abstract

This article examines the influence of various factors on the precision of 3D printed objects produced through Fused Filament Fabrication (FFF) using Polylactic Acid (PLA) as the primary material. While PLA is widely chosen for its compatibility with biological applications, it does suffer from limited dimensional accuracy. The study focuses on investigating the effects of four independent parameters, namely layer height, infill density, printing speed, and the number of top and bottom layers, on accuracy along the three axes of length, width, and depth. The research objective is to identify the optimal levels of these parameters that minimize dimensional errors across all axes. However, due to conflicting requirements among different dimensions, determining a comprehensive decision-making methodology presents a significant challenge. To address this issue, three distinct approaches are proposed, each offering a unique perspective and practical application. Interestingly, the outcomes of these approaches converge on a single solution. Among these parameters, printing speed emerges as the dominant factor, while, the number of layers is the least influential. Moreover, consistent shrinkage is observed in the length and width dimensions, with greater errors evident in longer dimensions. Overall, a preference for lower layer height and infill density, along with higher printing speed and increased top and bottom layers, is recommended. The study findings indicate that the most effective parameter selection for reducing errors in all dimensions involves a layer height of 0.2 mm, infill density of 60%, printing speed of 50 mm/s, and the use of four top and bottom layers.