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The purpose of this paper is to investigate the effect of process parameters of fused deposition modelling (FDM) 3D printing process on viscoelastic responses (creep compliance and recoverable compliance) of FDM built parts using a novel experimental design technique.

As part of the process characterization, a recently developed class of three-level design methodology – definitive screening design (DSD) – was used in this study to fit a second-order polynomial regression model. Artificial neural network (ANN) was also used to determine the optimal process parameters to improve creep compliance and recoverable compliance. The relationship between layer thickness, air gap, raster angle, build orientation, road width, number of contours and creep performance of FDM fabricated part was thereafter established empirically. Scanning electron microscope (SEM) is used to examine and characterize the morphology of the structures for some samples.

This study found that the creep resistance of FDM-manufactured part is significantly influenced by layer thickness, air gap, raster angle and number of contours and it can be improved by optimizing the settings of the selected parameters. The relationship between FDM process parameters and creep properties was determined, with the best creep performance observed by using 0.127 mm of layer thickness, zero air gap, zero raster angle, build orientation of 17.188°, road width of 0.4572 mm and 10 contours. Finally, the result is verified by confirmation experiments. The results prove that a DSD is a very effective design in characterizing the influence of process parameters on creep properties of FDM-built part at the lowest cost.

The originality of this paper lies in characterizing and optimizing the effect of process parameters on creep performance of FDM manufactured part that has not been studied in all previous studies. The paper highlights, for the first time, how the application of DSD can overcome most of the limitations encountered in the conventional techniques. This study can be used as a guide to the different additive manufacturing users of various industries and the results provide a good technical database on how FDM process parameters influence the creep performance of manufactured parts.

Fused deposition modeling (FDM) has become an increasingly important process among the available additive manufacturing technologies in various industries. Although there are many advantages of FDM process, a downside of its industrial application is the attainable dimensional accuracy with tight tolerance without compromising the mechanical performance. This paper aims to study the effects of six FDM operating parameters on two conflicting responses, namely, dynamic stiffness and dimensional stability of FDM produced PC-ABS parts. This study also aims to determine the optimal process settings using graphical optimization that satisfy the dynamic mechanical properties without compromising the dimensional accuracy.

The regression models based upon IV-optimal response surface methodology are developed to study the variation of dimensional accuracy and dynamic mechanical properties with changes in process parameter settings. Statistical analysis was conducted to establish the relationships between process variables and dimensional accuracy and dynamic stiffness. Analysis of variance is used to define the level of significance of the FDM operating parameters. Scanning electron microscope and Leica MZ6 optical microscope are used to examine and characterize the morphology of the structures for some specimens.

Experimental results highlight the individual and interaction effects of processing conditions on the dynamic stiffness and part accuracy. The results showed that layer thickness (slice height), raster-to-raster air gap and number of outlines have the largest effect on the dynamic stiffness and dimensional accuracy. The results also showed an interesting phenomenon of the effect of number of contours and the influence of other process parameters. The optimal process conditions for highest mechanical performance and part accuracy are obtained.

The effect of FDM processing parameters on the properties under dynamic and cyclic loading conditions has not been studied in the previous published work. Furthermore, simultaneous optimization of dynamic mechanical properties without compromising the dimensional accuracy has also been investigated. On the basis of experimental findings, it is possible to provide practical suggestions to set the optimal FDM process parameters in relation to dynamic mechanical performance, as well as the dimensional accuracy.

Additive manufacturing (AM) technology has a huge influence on the real world because of its ability to manufacture massively complicated geometrics. The purpose of this study is to use CiteSpace (CS) visual analysis to identify fused deposition modeling (FDM) research and development patterns to guide researchers to decide future research and provide a framework for corporations and organizations to prepare for the development in the rapid prototyping industry. Three-dimensional printing (3DP) is defined to budget minimize manufactured input and output for aviation and the medical product industrial sectors. 3DP has implemented its potential in the Coronavirus Disease of 2019 (COVID-19) reaction.

First, 396 original publications were extracted from the web of science (WOS) with the comprehensive list and did scientometrics analysis in CS software. The parameters are specified in CS including the span (from 2011 to 2019, one year slice for the co-authorship and the co-accordance analysis), visualization (show the merged networks), specific criteria for selection (top 20%), node form (author, organization, region, reference cited; cited author, journal and keywords) and pruning (pathfinder and slicing network). Finally, correlating data was studied and showed the results of the visualization study of FDM research were shown.

The framework of FDM information is beginning to take shape. About hot research topics, there are “Morphology,” “Tensile Property by making Blends,” “Use of Carbon nanotube in 3DP” and “Topology optimization.” Regarding the latest research frontiers of FDM printing, there are “Fused Filament Fabrication,” “AM,” in FDM printing. Where “Post-processing” and “environmental impact” are the research hotspots in FDM printing. These research results can provide insight into FDM printing and useful information to consider the existing studies and developments in FDM researchers’ analysis.

Despite some important obtained results through FDM-related publications’ visualization, some deficiencies remain in this research. With >99% of articles written in English, the input data for CS was all downloaded from WOS databases, resulting in a language bias of papers in other languages and neglecting other data sources. Although, there are several challenges being faced by the FDM that limit its wide variety of applications. However, the significance of the current work concerning the technical and engineering prospects is discussed herein.

First, the novelty of this work lies in describing the FDM approach in a Scientometric way. In Scientometric investigation, leading writers, organizations, keywords, hot research and emerging knowledge points were explained. Second, this research has thoroughly and comprehensively examined the useful sustainability effects, i.e. economic sustainability, energy-based sustainability, environmental sustainability, of 3DP in industrial development in qualitative and quantitative aspects by 2025 from a global viewpoint. Third, this work also described the practical significance of FDM based on 3DP since COVID-19. 3DP has stepped up as a vital technology to support improved healthcare and other general response to emergency situations.