Authors :
J. Sethubathi; G. Dhayanithi
Volume/Issue :
ICMST-2025
Google Scholar :
https://tinyurl.com/22y423xe
Scribd :
https://tinyurl.com/n5c6naaf
DOI :
https://doi.org/10.38124/ijisrt/25nov748
Abstract :
Additive Manufacturing (AM) has emerged as a transformative fabrication technology enabling rapid prototyping
and custom production of complex geometries. Among various AM processes, Fused Deposition Modeling (FDM) remains
the most widely adopted due to its simplicity, cost-effectiveness, and material versatility. However, achieving an optimal
balance between print quality and mechanical performance continues to be a major challenge. This research investigates
the influence of different nozzle diameters (0.2 mm, 0.4 mm, 0.6 mm) on the mechanical strength and surface quality of 3D-
printed PLA components. Standardized tensile specimens were fabricated under controlled conditions, with constant
parameters such as infill density, layer height, and printing speed. Tensile testing, surface roughness measurement, and
dimensional accuracy evaluations were conducted. Statistical modeling using Response Surface Methodology (RSM) and
Analysis of Variance (ANOVA) was applied to optimize parameters. Results indicate that smaller nozzles yield superior
surface quality, while larger nozzles enhance interlayer adhesion and tensile strength. The optimal trade-off was found at a
0.4 mm nozzle diameter, achieving high strength and acceptable print quality. This study provides practical insights for
additive manufacturing users seeking to optimize process performance.
Keywords :
Additive Manufacturing, Fused Deposition Modeling, Nozzle Diameter, Surface Roughness, Tensile Strength, Optimization, Response Surface Methodology, PLA.
Additive Manufacturing (AM) has emerged as a transformative fabrication technology enabling rapid prototyping
and custom production of complex geometries. Among various AM processes, Fused Deposition Modeling (FDM) remains
the most widely adopted due to its simplicity, cost-effectiveness, and material versatility. However, achieving an optimal
balance between print quality and mechanical performance continues to be a major challenge. This research investigates
the influence of different nozzle diameters (0.2 mm, 0.4 mm, 0.6 mm) on the mechanical strength and surface quality of 3D-
printed PLA components. Standardized tensile specimens were fabricated under controlled conditions, with constant
parameters such as infill density, layer height, and printing speed. Tensile testing, surface roughness measurement, and
dimensional accuracy evaluations were conducted. Statistical modeling using Response Surface Methodology (RSM) and
Analysis of Variance (ANOVA) was applied to optimize parameters. Results indicate that smaller nozzles yield superior
surface quality, while larger nozzles enhance interlayer adhesion and tensile strength. The optimal trade-off was found at a
0.4 mm nozzle diameter, achieving high strength and acceptable print quality. This study provides practical insights for
additive manufacturing users seeking to optimize process performance.
Keywords :
Additive Manufacturing, Fused Deposition Modeling, Nozzle Diameter, Surface Roughness, Tensile Strength, Optimization, Response Surface Methodology, PLA.
