Parameter optimization for PETG/ABS bilayer tensile specimens in material extrusion 3D printing through orthogonal method

Fused deposition modeling is a rapidly evolving manufacturing technique that can produce products with complex geometries in minimum waste. However, the limited material selections and poor quality in the products from this technique restrict its applications. Many researchers have found some parameters affecting single-material specimen mechanical properties, layer thickness, infill density, and printing speed. However, few manufacturing parameter studies have examined dual-material products. This study used acrylonitrile butadiene styrene and polyethylene-terephthalate-glycol to fabricate dual-material samples because of their characteristics. All samples were first fabricated half-thickness acrylonitrile butadiene styrene base with polyethylene-terephthalate-glycol part fabricated onto, since the functionalities from both can be obtained from this configuration. Sixteen batches were produced in relation to printing speed, layer thickness, and infill density using the orthogonal method, followed by parameter optimization and a verification test. The batch with the parameters of 30 mm/s printing speed, 0.1 mm layer thickness, and 75% infill density produced the best combination for samples (the highest tensile strength (44.73 MPa) and Young’s modulus (758.12 MPa)). This run finished fabrication in 113 min, faster than run 9 in the orthogonal method, which had the highest tensile performance of the 16 runs. The morphologies agreed the results and found a lower layer thickness increased layers in fabrication with less pores and voids. This research on FDM-produced multi-material specimens’ mechanical properties increases the likelihood that this technique will be used in future manufacturing.