Optimization of fused deposition modeling process parameters for dimensional accuracy using I-optimality criterion

Fused deposition modeling (FDM) is one of the widely used additive manufacturing technologies because it has flexibility and ability to build complex parts. The accuracy of parts fabricated by FDM is greatly influenced by various process parameters. FDM process has a complex mechanism in building parts and often poses difficulty in understanding adequately how conflicting FDM parameters will determine part quality and accuracy. Sectors such as medical implant, telecommunication, electronics and aerospace require increasingly higher levels of dimensional accuracy. Thus, traditional methods of ensuring quality do not effectively address global markets and customer's needs. This study proposes an I-optimality criterion for the optimization of FDM process parameters in order to address the limitations of the commonly used traditional designs. This study also aims to develop mathematical models in order to establish nonlinear relationship between process parameters and dimensional accuracy. The results show that I-optimality criterion is very promising technique in FDM process parameter optimization. Confirmation experiments show that the proposed method has great advantages in the aspect of both accuracy and efficiency compared with traditional methods proposed in previous studies.