Process Parameters Optimization for Hybrid Manufacturing of PLA Components, with Improved Surface Quality

This paper presents a new method of process parameters optimization, adequate for 3D printing of PLA (Polylactic Acid) components. The authors developed a new Hybrid Manufacturing Equipment (HME), suitable for producing complex parts made from a biodegradable thermoplastic polymer, for environmental sustainability. Our new HME equipment is producing PLA parts by both additive and subtractive techniques, with the aim of obtaining accurate PLA components with a good surface quality. A design of experiments has been applied for optimization purposes. The following manufacturing parameters were analyzed: rotation of the spindle, cutting depth, feed rate, layer thickness, nozzle speed, and surface roughness. Linear regression models and neural network models were developed to improve and predict the surface roughness of the manufactured parts. A new test part was designed and manufactured from PLA, to validate the new mathematical models, which can now be applied for producing complex parts made from polymer materials.