Mechanical strength predictability of full factorial, Taguchi, and Box Behnken designs: Optimization of thermal settings and Cellulose Nanofibers content in PA12 for MEX AM

Optimization of reinforced nanocomposites for MEX 3D-printing remain strong industrial claims. Herein, the efficacy of three modeling methods, i.e., full factorial (FFD), Taguchi (TD), and Box-Behnken (BBD), on the performance of MEX 3D printed nanocomposites was investigated, aiming to reduce the experimental effort. Filaments of medical-grade Polyamide 12 (PA12) reinforced with Cellulose NanoFibers (CNF) were evolved. Besides the CNF loading, 3D printing settings such as Nozzle (NT) and Bed (BΤ) Temperatures were optimization goals aiming to maximize the mechanical response. Three parameters and three levels of FFD were compliant with the ASTM-D638 standard (27 runs, five repetitions). An L9 orthogonal TD and a 15 runs BBD were compiled. In FFD, wt.3%CNF, 270 °C NT, and 80 °C BΤ led to 24% higher tensile strength compared to pure PA12. TGA, RAMAN, and SEM analyses interpreted the reinforcement mechanisms. TD and BBD exhibited fair approximations, requiring 7.4% and 11.8% of the FFD experimental effort. [Display omitted] •Mechanically reinforced Polyamide 12 (PA12)/Cellulose Nanofibers (CNF).•Medical grade biofriendly nanocomposite, by screw extrusion melt-mixing.•Optimal nozzle and bed temperature settings in MEX 3D printing.•Taguchi and Box Behnken experimental designs versus full factorial strategy.