Optimization of fused deposition modeling parameters to fabricate morphogenesis light weight structure with high tensile and compression strength

Fused deposition modeling (FDM) is a contemporary approach that can produce simple and complex physical models, prototype tools, and functional components. However, the challenge is choosing the right parameters, which are essential to printing a high-quality Additive Manufactured (AM) structure with acceptable mechanical attributes, like mechanical strength. In the additive manufacturing technique, fabricating a lightweight structure without compromising the weight and shape is very difficult because the significant parameter is infill density (D) %, which is directly proportional to the strength and inversely proportional to the weight. In this research based on morphogenesis, the infill density is varied at different locations wherever it is needed to print a lightweight, high-strength structure. Parameters Layer Thickness (LT), Shell Thickness (ST), and D were chosen, and experiments were conducted as per Central Composite Design (CCD). Tensile Strength (TS) and Compression Strength (CS) samples were printed with PLA and tested. The results were used to develop a multi-objective function. To predict maximum TS and CS without compromising the weight, Particle Swarm Optimization (PSO) and Response Surface Methodology (RSM) techniques were used to solve the multi-objective function. PSO predicts that the optimum printing parameter values for achieving a lightweight, high-strength structure are LT of 0.17 mm, ST of 0.91 mm, and D of 11.3%. These predicted results were confirmed through experiments.