Parametric Optimization of the 3D Printing Process for Dimensional Accuracy of Biopolymer Parts Using the Grey–Taguchi Method

The continuous usage of non-degradable and toxic polymers in today's industry has proven a significant barrier to better ecological sustainability. Considering this fact, today's prime requirement is to replace these traditional petroleum-based polymers with bio-based polymers that are environmentally friendly. Therefore, polylactic acid is used as a biopolymer to overcome the problem mentioned above because PLA is non-toxic, biodegradable, and has excellent mechanical properties. In this article, a parametric setting of a large number of process parameters of fused deposition modelling (FDM), which is an economical industrial 3D printing technology, achieves dimensional accuracy of a PLA-printed sample along the length ( x ), gauge width, ends width ( y ), and thickness ( z ). Taguchi's L27 orthogonal array, an experimental design, has been selected to conduct experiments. The variance analysis (ANOVA) has then used to analyse the influence of parameters on each performance characteristic. Subsequently, grey relational analysis (GRA) ascertains a combined set of optimal levels of process parameters to fabricate overall dimensionally accurate tensile specimens. After investigation, the optimal levels of process parameters have obtained as 0.1-mm layer height, grid infill pattern, line pattern of top and bottom layers, four number of top and bottom layers, 50% infill density, 125% flow, two number of shells, printing temperature of 200 °C, build plate temperature of 55 °C, print speed of 80 mm/s, and 50% capacity of cooling fan speed. The final step involved fabricating dimensionally conformed automobile door handles made of biopolymer using the optimal process parameters identified by GRA.