Modeling of RP-FDM Using Response Surface Methodology to Predict the Influence of Process Parameters on Porosity

Rapid Prototyping (RP) is a class of emerging technologies in which three-dimensional parts are built directly from computer solid models without going through traditional manufacturing steps such as process planning, tool manufacturing etc. Fused Deposition Modeling (FDM), a type of Rapid Prototyping technique is a complex technology Involving many different process parameters. These parameters have great influence on the quality of parts. The porosity of a part has a great effect on the functionality of parts. In this paper a mathematical model has been developed using Response Surface Methodology (RSM) and regression analysis to predict the influence of various process parameters on the porosity of the parts produced by FDM technique. The effect of input parameters such as slice thickness, road width, and model temperature and air gap on porosity is investigated using this mathematical model. The experimental results are statistically analyzed to determine significant factors and their interactions. Conducting experiments using specific combination of the levels of the significant factors does validation. Experimental values and tests of hypothesis demonstrate that the model developed has a satisfactory goodness of fit.