Investigation of an Optimal Material Addition Rate for Energy Consumption and Dimensional Accuracy in Fused Filament Fabrication of CFR-PEEK

The material addition rate (MAR) of fused filament fabrication (FFF) is an indicator of process efficiency varied by process parameter settings, which affects energy consumption and part quality in FFF. This study aims to identify the optimal MAR of FFF using carbon-fiber-reinforced polyether-ether-ketone (CFR-PEEK) by considering a trade-off between energy consumption and the dimensional accuracy of FFF outputs. A design of experiments considering two main process parameters is planned to print three sample types through FFF for CFR-PEEK. Then, the MAR (i.e., deposited material volume per build time) of FFF is obtained to derive individual regression models of energy consumption and the dimensional accuracy measured for each sample type. Furthermore, a trade-off between energy consumption and dimensional accuracy on the MAR is formulated to derive an optimal MAR for each sample type. The results show that FFF for CFR-PEEK has a trade-off between energy consumption and dimensional accuracy; there exists a specific MAR that maximizes the overall performance of energy consumption and dimensional accuracy for each sample type. The optimal MAR is the highest for the small volume sample, whereas it becomes the lowest for the vertical build orientation sample. This study suggests that the optimal MAR should be flexibly adjusted based on a fabricated part. The findings from this study also address the fact that decision-making for optimal FFF operations needs a transition from the identification of specific process parameter settings to the management of a proper process efficiency level in FFF.