Optimizing tensile strength and energy consumption for FDM through Mixed-Integer Nonlinear Multi-objective optimization and design of experiments.

This study presents a methodology for optimizing key parameters of a fused deposition modeling (FDM) printer to minimize energy consumption (EC) while exceeding a specified tensile strength (TS) threshold. Employing Design of Experiments (DoE) with Taguchi and Response Surface analysis, we identify influential parameters affecting TS and EC. A Mixed-Integer Nonlinear Multi-Objective Optimization model is then utilized to balance TS and EC, resulting in optimal parameter values. Validation using fabricated specimens demonstrates less than 5 % error in Tensile Strength and less than 2 % error in Energy Consumption, confirming the efficacy of the proposed methodology.