Experimental investigations and dimensional analysis modeling for mechanical properties of polycarbonate samples developed by fused filament fabrication process

Fused filament fabrication (FFF), a known variation of fused deposition modeling (FDM), is a fast-growing additive manufacturing technique that is widely used in various industrial and technological applications owing to its ability to build functional parts with complex geometrical features in a reasonably good time. FFF utilizes a variety of thermoplastic materials such as polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), nylon (polyamide), and polycarbonate (PC) each offering distinct properties suitable for different applications. Polycarbonate is a high-performance polymer with engineering applications, but it is a less studied material with respect to the FFF process. The mechanical properties and dimensional accuracy of FFF-built parts are influenced by several process parameters, and choosing the best set of process parameters is essential for achieving the desired properties in the built parts. This study examined the effects of four critical process parameters (layer thickness, extrusion temperature, printing speed, and extrusion width) on the mechanical properties such as the tensile, flexural, and compression strengths of FFF-printed polycarbonate specimens. Tensile, flexural, and compressive tests were performed according to ASTM standards. Mathematical models based on dimensional analysis were developed to determine the correlation between the process parameters and mechanical properties of the printed specimen. The predicted models obtained showed a good correlation with the measured values and could be used to generalize the prediction for the process conditions of the FFF process. Validation tests were conducted to verify the developed mathematical models. The developed mathematical models provide a tool for optimizing the manufacturing parameters during the fused filament fabrication process.