FDM Process Optimisation for Low Surface Roughness and Energy Consumption

This paper reports on an experiment-based investigation into the effect of different process parameters on the performance of the FDM process. In particular, the influence of five process parameters, namely infill percentage, layer thickness, printing speed, printing temperature and surface inclination angle, were examined and the resultant surface roughness and energy consumption were utilized as quality marks. Statistical study and ANOVA analysis of the experimental results were conducted and the influence of the examined parameters and their interaction effects were discussed and the optimal parameters for minimum surface roughness and energy consumption were identified. It is found that the surface inclination angle is the most significant parameter affecting the achievable surface roughness followed by the layer thickness and printing speed. Nevertheless, printing speed is found to be the most significant factor on the energy consumption while layer thickness came second, followed by the interaction effect of the layer thickness and printing temperature.