Fused deposition modeling (FDM) process parameter optimization for mechanical properties of 3D-printed woven fabric structures using Taguchi method

Fused deposition modeling (FDM) process parameters influence the mechanical behavior of the printed parts. Optimization of parameters like extrusion temperature, layer height, print speed and infill density enhances the performance of the product. The ability to process a variety of thermoplastic materials and quick and personalized design makes FDM a desirable alternative process to manufacture fabric structures. However, the mechanical properties are often compromised. This research attempts to optimize extrusion temperature, layer height and print speed for manufacturing of 2/1 twill woven fabric structure for desired properties. In this work, Taguchi robust design is used for experimental design. Samples from Polylactic acid (PLA) are subjected to tensile and flexural loading. Tensile strength, tensile modulus, flexural strength and flexural modulus are recorded and optimized using commercial software MINITAB. The order of influence of process parameters on fabric is varied for different properties evaluated. Either extrusion temperature or layer height is reported to be the most influential process parameter for the fabric sample. In contrast, print speed does not have significant effect on most of the properties studied. The mechanical properties and nature of influence by process parameters are found to be dissimilar in warp and weft direction.