Multi-response optimization of the dimensional and mechanical properties of 3D-printed polylactic acid part by response surface methodology

Industrial parts often demand high dimensional accuracy and mechanical strength. This study introduces a method using Response Surface Methodology and composite desirability to simultaneously optimize these performances in components manufactured through additive processes. The approach was validated on Polylactic Acid parts fabricated through Fused Filament Fabrication. Optimized process parameters included a print speed of 80 mm/s, a layer height of 0.2 mm, a fan speed of 50%, and an extrusion temperature of 210 °C, yielding tensile strength of 53.27 MPa and dimensional deviations under 5%. Experimental validations showed less than a 5% deviation between predictions and outcomes. The findings provide valuable insights into improving the quality and performance of printed components in various industrial applications, such as gears, highlighting the significance of multi-response optimisation in 3D printing processes. This study ultimately contributes to more efficient and cost-effective manufacturing processes.