Effect of Process Parameters and Material Selection on the Quality of 3D Printed Products by Fused Deposition Modeling (FDM): A Review

Abstract

This work presents an investigation on the quality of parts manufactured using fused deposition modeling (FDM), which is influenced by a large number of different elements. Some of which are based on the materials used in the production of the part, though others are rather pertinent to the process parameters. The manufacturing process and filament formulation has also a significant impact on the cost of the final product, as well as its physical, mechanical, and thermal properties. As the result, judicious combination of parameters can effectively act toward fine-tuning FDM toward three-dimensional printing (3DP) of pieces with quality fit-for-application. In this sense, the use of design of experiments (DOEs) is often needed for the purpose. Printing process parameters, including layer height, wall thickness, temperature, printing velocity, and tool path, have been discussed, in the understanding that 3DP time increases with decreasing layer thickness, and in turn increases production time and overall cost. A specific account is given on recent developments increasingly and more thoroughly focused on recognizing the impact of the process parameters and raw materials on the final product.