Enhancing 3D Printing Copper-PLA Composite Fabrication via Fused Deposition Modeling through Statistical Process Parameter Study
Abstract
:1. Introduction
2. Materials and Methods
2.1. Design of Experiments
2.2. Experimental Work
3. Results and Discussion
3.1. Maximum Failure Load
3.2. Percentage of Elongation at Break
3.3. Weight
4. Optimization
5. Conclusions
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Variable | Notation | Unit | −2 | −1 | 0 | 1 | 2 |
---|---|---|---|---|---|---|---|
Infill percentage | IP | % | 10 | 20 | 30 | 40 | 50 |
Fill Pattern | P | type | Grid | Triangle | Tri-Hexagonal | Cubic-Subdivision | Lines |
Layer thickness | LT | mm | 0.1 | 0.2 | 0.3 | 0.4 | 0.5 |
NO | Input Variables | Output Variables | |||||||
---|---|---|---|---|---|---|---|---|---|
Coded Values | Actual Values | Weight (g) | Maximum Failure Load (N) | Percentage of Elongation at Break | |||||
IP (%) | P (Type) | LT (mm) | IP (%) | P (Type) | LT (mm) | ||||
#1 | −1 | 1 | −1 | 20 | Cubic-Subdivision | 0.2 | 12.004 | 170 | 0.5232 |
#2 | 2 | 0 | 0 | 50 | Tri-Hexagonal | 0.3 | 16.3556 | 185 | 0.34146 |
#3 | 0 | 0 | 0 | 30 | Tri-Hexagonal | 0.3 | 14.1908 | 210 | 0.35971 |
#4 | 0 | 0 | 0 | 30 | Tri-Hexagonal | 0.3 | 15.01 | 210 | 0.41526 |
#5 | 0 | 0 | −2 | 30 | Tri-Hexagonal | 0.1 | 11.5934 | 165 | 0.4862 |
#6 | 0 | 0 | 2 | 30 | Tri-Hexagonal | 0.5 | 18.0406 | 230 | 0.49601 |
#7 | 1 | −1 | 1 | 40 | Triangle | 0.4 | 17.0612 | 230 | 0.42429 |
#8 | 1 | −1 | −1 | 40 | Triangle | 0.2 | 14.3308 | 205 | 0.45558 |
#9 | −1 | −1 | −1 | 20 | Triangle | 0.4 | 16.3048 | 210 | 0.39487 |
#10 | −1 | −1 | −1 | 20 | Triangle | 0.2 | 12.3236 | 190 | 0.41526 |
#11 | 1 | −1 | −1 | 40 | Cubic-Subdivision | 0.2 | 13.4913 | 208 | 0.4864 |
#12 | 0 | 0 | 0 | 30 | Tri-Hexagonal | 0.3 | 14.9346 | 218 | 0.39094 |
#13 | 0 | 2 | 0 | 30 | Lines | 0.3 | 15.1088 | 205 | 0.42526 |
#14 | 1 | 1 | 1 | 40 | Cubic-Subdivision | 0.4 | 16.6574 | 219 | 0.37185 |
#15 | −2 | 0 | 0 | 10 | Tri-Hexagonal | 0.3 | 13.845 | 180 | 0.42133 |
#16 | 0 | −2 | 0 | 30 | Grid | 0.3 | 15.0386 | 212 | 0.39705 |
#17 | −1 | 1 | 1 | 20 | Cubic-Subdivision | 0.4 | 15.9478 | 210 | 0.48588 |
Source | Sum of Squares | Degrees of Freedom | Mean Square | F-Value | p-Value | |
---|---|---|---|---|---|---|
Model | 4.276 × 1010 | 9 | 4.751 × 109 | 12.52 | 0.0015 | significant |
A-Infill percentage | 1.825 × 109 | 1 | 1.825 × 109 | 4.81 | 0.0644 | |
B-Pattern | 2.852 × 109 | 1 | 2.852 × 109 | 7.52 | 0.0288 | |
C-Layer thickness | 2.851 × 1010 | 1 | 2.851 × 1010 | 75.14 | <0.0001 | |
AB | 7.423 × 108 | 1 | 7.423 × 108 | 1.96 | 0.2046 | |
AC | 8.135 × 107 | 1 | 8.135 × 107 | 0.2144 | 0.6574 | |
BC | 1.250 × 109 | 1 | 1.250 × 109 | 3.29 | 0.1124 | |
A² | 8.463 × 109 | 1 | 8.463 × 109 | 22.31 | 0.0022 | |
B² | 1.762 × 108 | 1 | 1.762 × 108 | 0.4645 | 0.5175 | |
C² | 1.400 × 109 | 1 | 1.400 × 109 | 3.69 | 0.0962 | |
Residual | 2.656 × 109 | 7 | 3.794 × 109 | |||
Lack of Fit | 2.205 × 109 | 4 | 5.513 × 108 | 3.67 | 0.1569 | not significant |
Pure Error | 4.506 × 108 | 3 | 1.502 × 108 | |||
Cor Total | 4.542 × 1010 | 16 | ||||
R-sq = 94.15% | R-sq (Adjusted) = 86.63% |
Source | Degrees of Freedom | F-Value | p-Value |
---|---|---|---|
Model | 9 | 6.61 | 0.0105 |
A-Infill percentage | 1 | 10.37 | 0.0147 |
B-Pattern | 1 | 0.3692 | 0.5626 |
C-Layer thickness | 1 | 0.5559 | 0.4802 |
AB | 1 | 21.67 | 0.0023 |
AC | 1 | 0.0187 | 0.8951 |
BC | 1 | 0.5866 | 0.4688 |
A² | 1 | 0.0683 | 0.8013 |
B² | 1 | 1.26 | 0.2992 |
C² | 1 | 19.99 | 0.0029 |
Residual | 7 | ||
Lack of Fit | 4 | 0.8364 | 0.5821 |
Pure Error | 3 | ||
Cor Total | 16 | ||
R-sq = 89.48% | R-sq (Adjusted) = 75.95% |
Source | Degrees of Freedom | F-Value | p-Value |
---|---|---|---|
Model | 3 | 138.54 | <0.0001 |
A-Infill percentage | 1 | 47.89 | <0.0001 |
B-Pattern | 1 | 0.6261 | 0.4430 |
C-Layer thickness | 1 | 362.84 | <0.0001 |
Residual | 13 | ||
Lack of Fit | 10 | 0.3611 | 0.9031 |
Pure Error | 3 | ||
Cor Total | 16 | ||
R- Squared = 96.97% | Adj R-Squared = 95.04% |
Parameter/Response | Goal | Lower | Upper | Importance | |
---|---|---|---|---|---|
Parameter | Layer thickness | In range | 50 | 10 | - |
Raster angle | In range | 2 | −2 | - | |
Infill percentage | In range | 0.5 | 0.1 | - | |
Response | Part weight | Minimize | 18.0406 | 11.5934 | 3 |
Maximum failure load | Maximize | 230 | 165 | 3 | |
Elongation at break | Maximize | 0.5232 | 0.34146 | 3 |
Number | IP (%) | Pattern | LT (mm) | Weight | Maximum Failure Load | Percentage of Elongation at Break | Desirability | |
---|---|---|---|---|---|---|---|---|
1 | 32.909 | −2.000 | 0.152 | 12.617 | 205.999 | 0.523 | 0.810 | Selected |
2 | 33.052 | −2.000 | 0.153 | 12.642 | 206.182 | 0.524 | 0.810 | |
3 | 32.971 | −2.000 | 0.150 | 12.588 | 205.773 | 0.526 | 0.810 | |
4 | 33.298 | −2.000 | 0.146 | 12.527 | 205.292 | 0.533 | 0.809 | |
5 | 33.800 | −2.000 | 0.143 | 12.506 | 205.061 | 0.540 | 0.809 |
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Moradi, M.; Mehrabi, O.; Rasoul, F.A.; Mattie, A.A.; Schaber, F.; Khandan, R. Enhancing 3D Printing Copper-PLA Composite Fabrication via Fused Deposition Modeling through Statistical Process Parameter Study. Micromachines 2024, 15, 1082. https://doi.org/10.3390/mi15091082
Moradi M, Mehrabi O, Rasoul FA, Mattie AA, Schaber F, Khandan R. Enhancing 3D Printing Copper-PLA Composite Fabrication via Fused Deposition Modeling through Statistical Process Parameter Study. Micromachines. 2024; 15(9):1082. https://doi.org/10.3390/mi15091082
Chicago/Turabian StyleMoradi, Mahmoud, Omid Mehrabi, Fakhir A. Rasoul, Anas Abid Mattie, Friedemann Schaber, and Rasoul Khandan. 2024. "Enhancing 3D Printing Copper-PLA Composite Fabrication via Fused Deposition Modeling through Statistical Process Parameter Study" Micromachines 15, no. 9: 1082. https://doi.org/10.3390/mi15091082