Analytic hierarchy process to determine process parameters for optimal surface finish and dimensional accuracy

Fused Deposition Modeling (FDM) offers several advantages, such as the use of less expensive material and also the building of complex geometry. However, FDM has limitations, such as the appearance of seam lines between layers and the production of excess material residue leading to poor surface finish. This project introduces an alternative way to improve the surface roughness as well as the dimensional accuracy concurrently during the FDM process to improve the quality of the printed product. This paper applied the Analytic Hierarchy Process (AHP) method to determine the optimal process parameters for the FDM process for best surface roughness and dimensional accuracy. The AHP analysis has been conducted to calculate the weights of the different criteria that affect each factor (surface roughness and dimensional accuracy). The weights were verified by the consistency analysis and confirmed by referring to other studies. The layer thickness preserved the top of the list to both factors dimensional accuracy and surface finish. The extrusion temperature had the second rank of effectiveness to the dimensional accuracy, while it did not have a considerable effect on the surface finish. The build orientation is the second most effective creation in the surface finish while it is the third to the dimensional accuracy. The raster angle and raster width are the third and fourth effective criteria on the surface finish, respectively and the raster orientation is ranked as the fourth creation among the dimensional accuracy criteria. The fifth effective creation on the two factors is different. The AHP proof that the approach can be used to choose the optimal process parameters for the best surface finish and dimensional accuracy.