Optimization of process parameters in 3D printing of polycarbonate for high heat applications

This experimentation conducts for the optimization of Polycarbonate(PC) material 3D printing factors. The printing is done on the Flash Forge Guider 2 FDM equipment, employing the Taguchi methodology. The factors considered for optimization include infill rate (60%, 80%, 100%), film height (0.18 mm, 0.24 mm, 0.30 mm), and printing speed (40 mm/s, 60 mm/s, 80 mm/s). Tensile, compressive, and flexural experiments were performed to examine the mechanical properties of the printed objects. The experimental results revealed the highest tensile strength (39.106 MPa) at an infill rate of 100%, printing speed of 40 mm/s, and film thickness of 0.30 mm. As well as, the greatest compressive toughness (76.421 MPa) was produced at a fill density of 100%, printing rate of 60 mm/s, and layer thickness of 0.18 mm. The flexural toughness carried its peak (253.1 MPa) at an infill rate of 100%, printing rate of 40 mm/s, and film thickness of 0.30 mm. Using Signal-Noise (S/N) ratio charts, the maximum factors for improving tensile toughness were resolved as infill rate 100%, printing speed 40 mm/s, and film height 0.24 mm. For compressive toughness development, the maximum factors were detected as infill rate 100%, printing speed 60 mm/s, along with film height 0.18 mm. Flexural toughness optimization showed the infill rate 100%, printing speed 80 mm/s, along with film height 0.30 mm. Analysis of Variance (ANOVA) recommended the important contributions of every factor to the mechanical props. For tensile toughness, infill rate provides 93.37%, printing speed 0.121%, along with film height 4.17%. Compressive toughness development was provided to infill rate (87.48%), printing speed (3.81%), along with film height (2.38%). In the case of flexural toughness, infill rate provides 47.36%, printing speed 0.96%, along with film height 50%.