Process Parameter Optimization for Hybrid Manufacturing of PLA Components with Improved Surface Quality

This paper presents a new method of process parameter optimization, adequate for 3D printing of PLA (Polylactic Acid) components. The authors developed a new piece of Hybrid Manufacturing Equipment (HME), suitable for producing complex parts made from a biodegradable thermoplastic polymer, to promote environmental sustainability. Our new HME equipment produces PLA parts by both additive and subtractive techniques, with the aim of obtaining accurate PLA components with good surface quality. A design of experiments has been applied for optimization purposes. The following manufacturing parameters were analyzed: rotation of the spindle, cutting depth, feed rate, layer thickness, nozzle speed, and surface roughness. Linear regression models and neural network models were developed to improve and predict the surface roughness of the manufactured parts. A new test part was designed and manufactured from PLA to validate the new mathematical models, which can now be applied for producing complex parts made from polymer materials. The neural network modeling (NNM) allowed us to obtain much better precision in predicting the final surface roughness (Ra), as compared to the conventional linear regression models (LNM). Based on these modelling methods, the authors developed a practical methodology to optimize the process parameters in order to improve the surface quality of the 3D-printed components and to predict the actual roughness values. The main advantages of the results proposed for hybrid manufacturing using polymer materials like PLA are the optimized process parameters for both 3D printing and milling. A case study has been undertaken by the authors, who designed a specific test part for their new hybrid manufacturing equipment (HME), in order to test the new methodology of optimizing the process parameters, to validate the capability of the new HME. At the same time, this new methodology could be replicated by other researchers and is useful as a guideline on how to optimize the process parameters for newly developed equipment. The innovative approach holds potential for widespread equipment functionality enhancement among other users.