{"paper_id":"2f1b59cd-5dd8-4373-9908-f9b82748623e","body_text":"Multi-Objective Optimization of Fused Deposition Modelling Parameters to Balance Mechanical and Economic Performance | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Multi-Objective Optimization of Fused Deposition Modelling Parameters to Balance Mechanical and Economic Performance Mohamed Sherif, Hesham Mahmoud, Sameh Mekhiel, Ahmed Elmesalamy This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8167792/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 27 Apr, 2026 Read the published version in Progress in Additive Manufacturing → Version 1 posted You are reading this latest preprint version Abstract Additive manufacturing continues to expand its applications, targeting customization, optimization, and complexity across various industries. PLA-based materials are widely utilized in biomedical applications, including surgical guides, dental molds, and prosthetic connectors, where strength and reliability are essential. They are also commonly found in consumer products, such as eyewear, sports gear, and ergonomic tools. For these applications, achieving hi gh ultimate strength and superior surface quality is critical to enhancing durability, improving failure resistance, and reducing replacement frequency and associated costs. This study investigates the influence of process parameters in fused deposition modeling (FDM) on the performance of Polylactic acid (PLA), with attention to the cost-related factors. Ultimate tensile strength (UTS) and surface roughness are the performance metrics selected in this work to address the noted discrepancies and conflicting results in the literature related to them. Cost-effectiveness was evaluated through the analysis of material consumption and printing time. A fractional factorial screening experimental design was first conducted, followed by a central composite design (CCD) to assess main effects and parameter interactions. Build orientations and raster angle parameters were investigated using a novel approach that diverges from the traditionally applied discrete orientations. The experimental results were further analyzed using analysis of variance (ANOVA) and response surface methodology (RSM). Finally, a Multi-Objective Optimization (MOO) was conducted to identify optimized printing parameters according to a selected number of application scenarios. The findings provide new insights into optimizing FDM of PLA, offering a systematic framework to enhance both functional performance and manufacturing efficiency for polymeric end products. Additive manufacturing Fused deposition modelling Polymer testing Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Published Journal Publication published 27 Apr, 2026 Read the published version in Progress in Additive Manufacturing → Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {\"props\":{\"pageProps\":{\"initialData\":{\"identity\":\"rs-8167792\",\"acceptedTermsAndConditions\":true,\"allowDirectSubmit\":true,\"archivedVersions\":[],\"articleType\":\"Research Article\",\"associatedPublications\":[],\"authors\":[{\"id\":556246615,\"identity\":\"bc985205-bf24-45b3-b5a9-fd01c60299fe\",\"order_by\":0,\"name\":\"Mohamed 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PLA-based materials are widely utilized in biomedical applications, including surgical guides, dental molds, and prosthetic connectors, where strength and reliability are essential. They are also commonly found in consumer products, such as eyewear, sports gear, and ergonomic tools. For these applications, achieving hi\\u003c/p\\u003e\\u003cp\\u003egh ultimate strength and superior surface quality is critical to enhancing durability, improving failure resistance, and reducing replacement frequency and associated costs. This study investigates the influence of process parameters in fused deposition modeling (FDM) on the performance of Polylactic acid (PLA), with attention to the cost-related factors. Ultimate tensile strength (UTS) and surface roughness are the performance metrics selected in this work to address the noted discrepancies and conflicting results in the literature related to them.\\u003c/p\\u003e\\u003cp\\u003eCost-effectiveness was evaluated through the analysis of material consumption and printing time. A fractional factorial screening experimental design was first conducted, followed by a central composite design (CCD) to assess main effects and parameter interactions. Build orientations and raster angle parameters were investigated using a novel approach that diverges from the traditionally applied discrete orientations. The experimental results were further analyzed using analysis of variance (ANOVA) and response surface methodology (RSM). Finally, a Multi-Objective Optimization (MOO) was conducted to identify optimized printing parameters according to a selected number of application scenarios. 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