Investigating the Effect of Process Parameters and Optimizing the Build Time and Material Usage in FDM Using Cura

Fused Deposition Modelling (FDM) is one of the most popular Additive Manufacturing (AM) techniques for 3D printing. However, FDM is a complex process and based on many process parameters. Any small change in its process parameters can influence the part printing quality and material properties. There are limited investigations have been reported for exploring the effects of FDM process parameters on 3D printed parts. Therefore, it is crucial to investigate FDM process parameters to ensure the better quality of the 3D printed parts and to ensure this technology is successful for engineering applications. One of the most significant parameters of the FDM for 3D printing process is the raster angle and it is vital to investigate its effect on mechanical properties of 3D printed part. In this study, the five different raster angles are used to fabricate the 3D parts, and their tensile properties are investigated to identify the best raster position to fabricate the strongest 3D printing part. In this study, thermoplastic material - polylactic acid (PLA) is used. In this study, the micro structural analysis on fracture interface of the parts after tensile testing is performed using a scanning electron microscopy (SEM) to explain material failure modes and reasons. In this study, the micro-level structural changes on outer and inner surfaces of the 3D parts that are fabricated using the five different raster orientations are also examined in detail. This study identified the best raster orientation to lie down the layers of 3D printing material during the process. This study also identified that there are several defects in 3D printed parts at micro level that have large impact on mechanical properties of 3D printed part.