Selection of infill parameters considering their effects on operational and mechanical performance for material extrusion of CFR-PEEK

• Published in: Rapid prototyping journal 2023-07, Vol.29 (7), p.1471-1485
• Main Authors: Noh, Heena, Park, Kijung, Jeon, Hyun Woo
• Format: Article
• Language: English
• Subjects: Carbon fibers; Commodities; Cost control; Decision making; Density; Design of experiments; Energy consumption; Extrusion; Fiber reinforced polymers; Manufacturing; Mechanical properties; Multiple criterion; Parameter identification; Pareto optimum; Polyether ether ketones; Polymers; Rapid prototyping; Tensile strength; Tensile stress; Variance analysis
• ISSN: 1355-2546; 1355-2546; 1758-7670
• DOI: 10.1108/RPJ-11-2022-0380

Purpose As newer high performance polymers in mechanical properties become available for material extrusion-based additive manufacturing, determining infill parameter settings becomes more important to achieve both operational and mechanical performance of printed outputs. For the material extrusion of carbon fiber reinforced poly-ether-ether-ketone (CFR-PEEK), this study aims not only to identify the effects of infill parameters on both operational and mechanical performance but also to derive appropriate infill settings through a multicriteria decision-making process considering the conflicting effects. Design/methodology/approach A full-factorial experimental design to investigate the effects of two major infill parameters (i.e. infill pattern and density) on each performance measure (i.e. printing time, sample mass, energy consumption and maximum tensile load) is separately performed to derive the best infill settings for each measure. Focusing on energy consumption for operational performance and maximum tensile load for mechanical performance, the technique for order preference by similarity to ideal solution is further used to identify the most appropriate infill settings given relative preferences on the conflicting performance measures. Findings The results show that the honeycomb pattern type with 25% density is consistently identified as the best for the operational performance measures, while the triangular pattern with 100% density is the best for the mechanical performance measure. Moreover, it is suggested that certain ranges of preference weights on operational and mechanical performance can guide the best parameter settings for the overall material extrusion performance of CFR-PEEK. Originality/value The findings from this study can help practitioners selectively decide on infill parameters by considering both operational and mechanical aspects and their possible trade-offs.