Title: A study on the process optimisation of filament extrusion for 3-D printing applications

Authors: Ergin Erdem; Michael Kutzmonich; Aleks Stefaniak; Paul Badger; Arif Sirinterlikci; Gabriel Cotrell

Addresses: School of Engineering and Science, Robert Morris University, 6001 University Blvd., Moon Twp., PA 15108, USA ' School of Engineering and Science, Robert Morris University, 6001 University Blvd., Moon Twp., PA 15108, USA ' National Institute Occupational Safety and Health, Centers for Disease Control, 1000 Frederick Lane Morgantown, WV 26508, USA ' School of Engineering and Science, Robert Morris University, 6001 University Blvd., Moon Twp., PA 15108, USA ' School of Engineering and Science, Robert Morris University, 6001 University Blvd., Moon Twp., PA 15108, USA ' School of Engineering and Science, Robert Morris University, 6001 University Blvd., Moon Twp., PA 15108, USA

Abstract: In this study, we embark on a research on the optimisation of the filament extrusion process using statistical analysis. For this purpose, we develop our data collection scheme and corresponding precision and accuracy measures to assess the quality of the extruded filaments. The input factors are considered to be the type of the polymer (i.e., acrylonitrile butadiene styrene and polylactic acid), source of feedstock (i.e., recycled or virgin), and the extrusion temperature. The equipment utilised has been featured along with the developed performance measures. The interaction between polymer type and extrusion temperature has been found to significantly impact the precision of the filament. It has also been found that for polylactic acid, the feedstock obtained from virgin feedstock has lower variability with respect to filament diameter, whereas recycled feedstock has lower variability for acrylonitrile butadiene styrene filament.

Keywords: full factorial design; filament extrusion; additive manufacturing; accuracy; precision; process optimisation.

DOI: 10.1504/IJRAPIDM.2025.148809

International Journal of Rapid Manufacturing, 2025 Vol.10 No.2, pp.123 - 145

Received: 26 Feb 2024
Accepted: 05 Feb 2025
Published online: 25 Sep 2025 *

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