Optimizing the process parameters with statistical and soft computing techniques for enhanced mechanical properties of acrylonitrile butadiene styrene material samples fabricated via fused filament fabrication technique

This investigation presents an innovative methodology aimed at enhancing the tensile strength (TS) and compressive strength (CS) of acrylonitrile butadiene styrene (ABS) utilized in prosthetic socket fabrication. The study evaluates the effects of printing temperature (PT), feed rate (FR), and raster height (RH) on ABS properties via fused filament fabrication (FFF). Samples underwent both tensile and compression testing, followed by fractographic analysis. Statistical techniques including Taguchi’s analysis of variance (ANOVA) and response surface methodology (RSM) were applied. Empirical findings were integrated with soft computing techniques, specifically feedforward backpropagation artificial neural network (ANN) and adaptive neuro-fuzzy inference system (ANFIS). RH contributed 32.94% (TS) and 62.07% (CS), while PT and FR contributed 18.93 and 10.36% (TS), and 8.77 and 19.24% (CS) respectively. The ANFIS model, optimized with “Generalised Bell Membership Function” and “Hybrid optimization,” exhibited superior predictive performance, with the lowest RMSE of 0.04105 (TS) and 0.1709 (CS). These findings underscore ANFIS as the most accurate predictive tool, offering insights for parameter optimization and the optimized parameters are 0.1 mm RH, 240 °C PT, and 25 mm/s FR. Resulting configurations achieved a TS of 38.500 MPa and a CS of 181.05 MPa, enhancing prosthetic socket strength and functionality. This interdisciplinary approach establishes a robust framework for optimizing FFF parameters, advancing polymer investigations, and improving additive manufacturing (AM) accuracy. The study demonstrates the potential for enhancing prosthetic socket robustness and user comfort. The developed transtibial prosthetic socket, employing optimized parameters, serves as an application within prosthetics, laying the groundwork for further research advancements.