Effect of FFF parameters on PLA/WD composite properties: Comparative analysis using Taguchi and GRA approach

This article explores the optimization of 3D printing parameters of PLA/wood dust (PLA/WD) composite material for enhanced physical properties, including density, surface roughness, water absorption, and Shore D hardness. The study employs a Taguchi-based L27 orthogonal array design for experimentation, with mathematical models created using grey relational analysis (GRA) to predict the material’s performance by obtaining a grey relational grade (GRG). The obtained GRG was further optimized using ANOVA. The FFF input parameters analyzed include nozzle temperature (190–200°C), layer height (0.12–0.28 mm), print speed (30–50 mm/min), infill density (80–100%), and raster angle (0–90°). The results indicate that a printing temperature of 195°C, a layer thickness of 0.12 mm, a print speed of 30 mm/sec, 100% infill density, and a raster angle of 45° yield the highest GRG, signifying the best overall performance. Furthermore, the data obtained from Analysis of Variance (ANOVA) indicated that, raster angle has the most substantial influence on physical characteristics, followed by infill %, print speed, print temperature, and layer thickness. The investigation of the sample using Scanning Electron Microscopy (SEM) revealed aspects of the sample morphology, including layer bonding irregularities and empty spaces, which impact the density and hardness of the material.