Investigating Effects of Fused-Deposition Modeling (FDM) Processing Parameters on Flexural Properties of ULTEM 9085 using Designed Experiment

Fused-deposition modeling (FDM), one of the additive manufacturing (AM) technologies, is an advanced digital manufacturing technique that produces parts by heating, extruding and depositing filaments of thermoplastic polymers. The properties of FDM-produced parts apparently depend on the processing parameters. These processing parameters have conflicting advantages that need to be investigated. This article focuses on an investigation into the effect of these parameters on the flexural properties of FDM-produced parts. The investigation is carried out on high-performance ULTEM 9085 material, as this material is relatively new and has potential application in the aerospace, military and automotive industries. Five parameters: air gap, raster width, raster angle, contour number, and contour width, with a full factorial design of the experiment, are considered for the investigation. From the investigation, it is revealed that raster angle and raster width have the greatest effect on the flexural properties of the material. The optimal levels of the process parameters achieved are: air gap of 0.000 mm, raster width of 0.7814 mm, raster angle of 0°, contour number of 5, and contour width of 0.7814 mm, leading to a flexural strength of 127 MPa, a flexural modulus of 2400 MPa, and 0.081 flexural strain