Multi-Objective Optimization of Fused Deposition Modelling Parameters to Balance Mechanical and Economic Performance

Additive manufacturing continues to expand its applications, targeting customization, optimization, and complexity across various industries. PLA-based materials are widely utilized in biomedical applications, including surgical guides, dental molds, and prosthetic connectors, where strength and reliability are essential. They are also commonly found in consumer products, such as eyewear, sports gear, and ergonomic tools. For these applications, achieving high ultimate strength and superior surface quality is critical to enhancing durability, improving failure resistance, and reducing replacement frequency and associated costs. This study investigates the influence of process parameters in fused deposition modeling (FDM) on the performance of Polylactic acid (PLA), with attention to the cost-related factors. Ultimate tensile strength (UTS) and surface roughness are the performance metrics selected in this work to address the noted discrepancies and conflicting results in the literature related to them.Cost-effectiveness was evaluated through the analysis of material consumption and printing time. A fractional factorial screening experimental design was first conducted, followed by a central composite design (CCD) to assess main effects and parameter interactions. Build orientations and raster angle parameters were investigated using a novel approach that diverges from the traditionally applied discrete orientations. The experimental results were further analyzed using analysis of variance (ANOVA) and response surface methodology (RSM). Finally, a Multi-Objective Optimization (MOO) was conducted to identify optimized printing parameters according to a selected number of application scenarios. The findings provide new insights into optimizing FDM of PLA, offering a systematic framework to enhance both functional performance and manufacturing efficiency for polymeric end products.