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Sensitivity of Rp Surface Finish to Process Parameter Variation

In the rapid prototyping process, surface finish is critical as it can affect the part accuracy, reduce the post processing costs and improve the functionality of the parts. This paper presents an experimental design technique for determining the optimal surface finish of a part built by the Fused Deposition Modeling (FDM) process. The design investigates the effect of the parameters; build orientation, layer thickness, road width, air gap and model temperature on the surface finish. Experiments were conducted using a fractional factorial design with two levels for each factor. The results are statistically analyzed to determine the significant factors and their interactions. The significant factors, their interactions and the optimum settings are proposed.