Improving 3D Printing Geometric Accuracy Using Design of Experiments on Process Parameters in Fused Filament Fabrication (FFF)

This paper presents a statistical approach to improve the geometric accuracy of parts fabricated with a Fused Filament Fabrication (FFF), or also known as Fused Deposition Modelling (FDM) 3D printer. Design of Experiments (DoE) is used to develop the required statistical information and analyzing the experimental results. The paper provides an overview of the design process and the employed methodology including the design of the experiments, design of test samples, analyzing the experimental results, selection of the important process parameters, and the preliminary analyzes for the desired optimization of the process parameters. Customized design of the test samples made it possible to measure key features of the components quantifying the effect of the process parameters on the geometric accuracy resulting by the process. The outcome of the conducted Design of Experiments is a setting for selection of the process parameters to produce parts with considerably higher geometric quality. Variety of validation experiments are conducted and repeating the process under the selected parameters demonstrated that it is possible to achieve a desired level of reproducibility, using this 3D-Printing process.