Optimisation of HIPS material in fusion deposition modelling using the Taguchi-Grey approach

Additive Manufacturing (AM), specifically Fused Deposition Modelling (FDM), has become a highly promising method for creating intricate shapes using different materials. High Impact Polystyrene (HIPS) is notable for its tensile strength, flexibility, and resistance to high temperatures and chemicals, making it an ideal material for various applications. This study aims to optimise the process parameters of FDM for HIPS material using Taguchi Grey Relational Analysis (GRA) within the context of finite element modelling and simulation. The research investigates the effects of FDM process parameters—such as infill density, printing speed, and nozzle temperature—on key outcome variables like printing time, dimensional accuracy, and surface quality. A systematic series of experiments designed using the Taguchi method and optimised through GRA were conducted. The study identifies optimal parameter combinations that result in high-quality HIPS parts. Additionally, Grey Relational Grades elucidate the critical factors influencing AM process performance. This work contributes to the advancement of AM techniques, particularly FDM, for HIPS material by integrating empirical research with finite element analysis. The findings address the growing demand for efficient and cost-effective production across industries such as the aerospace, automotive, and medical sectors. The study offers valuable insights into parameter optimisation strategies applicable to a broad range of additive manufacturing applications, enhancing precision and performance in AM processes.