Modeling FDM Gear Printing: An Experimental Design-Based Mathematical Approach

Abstract

Gears, critical technological components found in most machines, require effective optimization during their manufacturing. This study examines the production of gears through the additive manufacturing process, specifically the Fused Deposition Modeling (FDM) technique. The two responses under scrutiny are manufacturing time and the amount of material consumed. The primary objective is to develop a mathematical model that correlates these two responses with four specific parameters (layer thickness, number of shells, and infill density). To achieve this objective, an experimental design was devised, followed by a statistical study aimed at formulating an appropriate mathematical model. Additionally, the mathematical model has been validated through residual verification, enhancing its reliability and suitability to the experimental data.