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<p>The fused deposition modelling (FDM) parameters for ABS components were optimised using a combined experimental and computational approach. A central composite design was used to fabricate 31 ASTM D638 Type IV tensile specimens by adjusting layer height, infill density, infill pattern, and printing speed. Elongation at failure varied from 5.1% to 13.1%, and tensile strength ranged from 21.6 to 26.9&#xa0;MPa. Layer height was identified as the primary driver of stiffness (linear coefficient = 170.4, <i>p</i> &lt; 0.001) and infill density as the primary factor governing strength (coefficient = 2.280, <i>p</i> &lt; 0.001) after Response Surface Methodology (RSM) generated models with R<sup>2</sup> values above 0.79. Elongation showed a U-shaped relationship with layer thickness (R<sup>2</sup> = 0.876), suggesting different ductility and strength regimes. Three-dimensional surface plots showed that the best conditions were for coarser layers (0.25–0.30&#xa0;mm) with moderate infill (60–75%) for improved ductility and layer heights of 0.10–0.15&#xa0;mm with high infill (85–90%) and a cubic pattern for maximum stiffness and strength. According to a multi-criteria analysis using the Order of Preference by Similarity to Ideal Solution (TOPSIS), the configuration with 0.15&#xa0;mm layer height, 80% infill, line pattern, and 175&#xa0;mm/min speed was the best performer overall. Scanning electron microscopy confirmed that lower densities encourage crack initiation by connecting void morphology to fracture behaviour. For adjusting FDM-printed ABS parts to application-specific mechanical requirements, the combined RSM–TOPSIS framework provides dependable predictive models and decision-making guidance.</p>

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Optimization of mechanical properties of 3D printed ABS: a comparative study of response surface methodology and TOPSIS

  • 期刊论文

  • 发表日期：

    2026年1月19日

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  • Vijay Chouhan,
  • Ratnesh Kumar Raj Singh,
  • Deepa Mudgal

摘要

The fused deposition modelling (FDM) parameters for ABS components were optimised using a combined experimental and computational approach. A central composite design was used to fabricate 31 ASTM D638 Type IV tensile specimens by adjusting layer height, infill density, infill pattern, and printing speed. Elongation at failure varied from 5.1% to 13.1%, and tensile strength ranged from 21.6 to 26.9 MPa. Layer height was identified as the primary driver of stiffness (linear coefficient = 170.4, p < 0.001) and infill density as the primary factor governing strength (coefficient = 2.280, p < 0.001) after Response Surface Methodology (RSM) generated models with R2 values above 0.79. Elongation showed a U-shaped relationship with layer thickness (R2 = 0.876), suggesting different ductility and strength regimes. Three-dimensional surface plots showed that the best conditions were for coarser layers (0.25–0.30 mm) with moderate infill (60–75%) for improved ductility and layer heights of 0.10–0.15 mm with high infill (85–90%) and a cubic pattern for maximum stiffness and strength. According to a multi-criteria analysis using the Order of Preference by Similarity to Ideal Solution (TOPSIS), the configuration with 0.15 mm layer height, 80% infill, line pattern, and 175 mm/min speed was the best performer overall. Scanning electron microscopy confirmed that lower densities encourage crack initiation by connecting void morphology to fracture behaviour. For adjusting FDM-printed ABS parts to application-specific mechanical requirements, the combined RSM–TOPSIS framework provides dependable predictive models and decision-making guidance.