A grey‐based Taguchi method to optimize fused deposition modelling process parameters for manufacture of a hip joint implant

Abstract

Controlling process parameters to configure a component has long been regarded as a value‐added function of additive manufacturing. Factors that contribute to the quality of total hip prostheses are the degree of dimensional accuracy, surface finish, and manufacturing time. In this study, Digmat‐additive manufacturing software has been used for finite element analysis to determine the quality of a fused deposition modelling printed carbon fiber polyamide 12 composite hip joint implant. The influence of three process parameters namely, printing temperature, layer height, print speed together with interactions were investigated using Taguchi's orthogonal array. The grey relational Taguchi method was used to optimize the process parameters on the part deflection and build time. The results showed that a printing temperature of 255 °C, a high layer thickness of 0.3 mm, and a print speed of 50 mm/s were optimum settings for both responses. Experimental work was carried out and the results used to validate the finite element results which showed good agreement. Microstructural analyses and surface analysis of printed parts were performed using scanning electron microscopy. The results identified that the surface texture of the manufactured implant was rough within the acceptable range for better bone‐to‐implant contact.