Safety-Oriented Optimization of Polymer Components in FDM Using MCDM

Raja  Subramani; Maher Ali  Rusho; Shahad Abdul  Wahhab Ibraheem; Hassan Safi  Ahmed; Kareem  Al-Adily; Mohsin  Ali; Maha H. Philip  Rahmani; Mohammed Ahmed  Mustafa; Tholfiqar Najah  Ismael

doi:10.6000/1929-5995.2025.14.19

Authors

Raja Subramani Center for Advanced Multidisciplinary Research and Innovation, Chennai Institute of Technology, Chennai, Tamilnadu, India
Maher Ali Rusho Lockheed Martin Engineering Management, University of Colorado, Boulder, Colorado-80308, USA
Shahad Abdul Wahhab Ibraheem Department of Radiological Technique, Al-Turath University, Baghdad, Iraq
Hassan Safi Ahmed Department of Medical Device Engineering, College of Medical Technology, Al-Farahidi University, Baghdad, Iraq
Kareem Al-Adily Al-Hadi University College, Baghdad, 10011, Iraq
Mohsin Ali Al-Zahrawi University College, Karbala, Iraq
Maha H. Philip Rahmani Department of Pharmaceutics, Al-Bayan University, College of Pharmacy, Baghdad, Iraq
Mohammed Ahmed Mustafa Department of Biology, College of Education, University of Samarra, 34010 Iraq
Tholfiqar Najah Ismael Department of Medical Instrumentation Engineering, Imam Jaafar Al-Sadiq University, Baghdad, Iraq

DOI:

https://doi.org/10.6000/1929-5995.2025.14.19

Keywords:

Fused Deposition Modeling (FDM), Polymer Components, Multi-Criteria Decision-Making (MCDM), Safety Optimization, Mechanical Properties, Process Parameter Optimization, Additive Manufacturing

Abstract

Fused deposition modeling (FDM) has become a widely adopted additive manufacturing method for producing functional polymer components across industrial and biomedical domains. However, ensuring both mechanical performance and safety reliability remains challenging due to the sensitivity of FDM outcomes to process parameters. This study proposes a decision-making framework integrating Fuzzy Analytic Hierarchy Process (AHP) and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) to optimize FDM process parameters—layer thickness, infill density, print speed, and extrusion temperature—based on mechanical and safety performance indicators. Experimental and decision analyses identified an optimal configuration of 0.2 mm layer thickness, 80% infill density, 60 mm/s print speed, and 220 °C extrusion temperature, resulting in a 17.6% improvement in tensile strength and a 14.3% increase in safety factor, calculated as the ratio of maximum tensile stress to yield stress, compared to baseline settings. The proposed framework provides a systematic pathway for balancing mechanical integrity and safety reliability in polymer additive manufacturing, offering practical value for industrial optimization and sustainable design.

References

Rathi M, Sharma A. Shaping the Future: Additive Manufacturing of Ceramics for Complex Geometries. Journal of Ceramics and Concrete Technology 2025; 10(2): ISSN: 2457-0826 (Online).

Kumar R, Mehdi H, Bhati SS, Arunkumar M, Mishra S, Lohumi MK. A comprehensive review of advancements in additive manufacturing for 3D printed medical components using diverse materials. Discover Materials 2025; 5(1): 1-29. DOI: https://doi.org/10.1007/s43939-025-00349-w

Fu K. What 3D Printing Cannot Achieve: Rethinking Composite Additive Manufacturing. Accounts of Materials Research 2025; 6(8): 921-926. DOI: https://doi.org/10.1021/accountsmr.5c00156

Yeshiwas TA, Tiruneh AB, Sisay MA. A review article on the assessment of additive manufacturing. Journal of Materials Science: Materials in Engineering 2025; 20(1): 85. DOI: https://doi.org/10.1186/s40712-025-00306-8

Maniraj M, Kumar SR. Design for Additive Manufacturing: Bridging Creativity and Precision in the 3D Printing Era. In: Modeling, Analysis, and Control of 3D Printing Processes. IGI Global Scientific Publishing 2025; 79-100. DOI: https://doi.org/10.4018/979-8-3373-0533-2.ch004

Dzogbewu TC, de Beer DJ, Nooni IK. Additive Manufacturing as a Catalyst for Low-Carbon Production and the Renewable Energy Transition in Electric Vehicles. Technologies 2025; 13(10): 428. DOI: https://doi.org/10.3390/technologies13100428

Zhang Z, Hu C, Qin QH. The improvement of void and interface characteristics in fused filament fabrication-based polymers and continuous carbon fiber-reinforced polymer composites: a comprehensive review. The International Journal of Advanced Manufacturing Technology 2025; 1-41.

Azami M, Aubin-Fournier PL, Hojjati M, Skonieczny K. Additive Manufacturing of PEEK/Lunar Regolith Composites for Sustainable Lunar Manufacturing. arXiv preprint arXiv:2508.00894; 2025.

Subramani R, Leon RR, Nageswaren R, Rusho MA, Shankar KV. Tribological Performance Enhancement in FDM and SLA Additive Manufacturing: Materials, Mechanisms, Surface Engineering, and Hybrid Strategies—A Holistic Review. Lubricants 2025; 13(7): 298. DOI: https://doi.org/10.3390/lubricants13070298

Qadyani MJ, Ameri B, Taheri-Behrooz F. Critical strain energy release rate in additively manufactured polymers through comparative study of ABS and PLA across various raster angles. Theoretical and Applied Fracture Mechanics 2025; 138: 104890. DOI: https://doi.org/10.1016/j.tafmec.2025.104890

Arunkumar P, Balaji D, Radhika N, Rajeshkumar L, Rangappa SM, Siengchin S. Effect of infill pattern on mechanical properties of 3D printed PLA-Zn composites for drone frame structures: A topology optimization integrated application study. Results in Engineering 2025; 25: 104107. DOI: https://doi.org/10.1016/j.rineng.2025.104107

Tomelleri F, Bosetti P, Brunelli M. Optimizing 3D printer selection through multi-criteria decision analysis. The International Journal of Advanced Manufacturing Technology 2025; 1-20. DOI: https://doi.org/10.1007/s00170-025-16148-9

Arivendan A, Chen X, Zhang YF, Keerthiveettil Ramakrishnan S, Gao W, Winowlin Jappes JT, Alagumalai V. Continuous Natural Fiber‐Reinforced Polymer Composites (CNFRPCs) Manufacturing: Additive Manufacturing Pathways to a Sustainable Future—A Critical Review. Polymer Composites 2025. DOI: https://doi.org/10.1002/pc.70308

Ma Q, Dong K, Li F, Jia Q, Tian J, Yu M, Xiong Y. Additive manufacturing of polymer composite millimeter‐wave components: Recent progress, novel applications, and challenges. Polymer Composites 2025; 46(1): 14-37. DOI: https://doi.org/10.1002/pc.28985

Gajević S, Miladinovic S, Jovanović J, Güler O, Özkaya S, Stojanovic B. Application of Various Optimisation Methods in the Multi-Optimisation for Tribological Properties of Al–B4C Composites. Computers, Materials & Continua 2025. DOI: https://doi.org/10.32604/cmc.2025.065645

Salaimanimagudam MP, Jayaprakash J, Anwar MP. Selection of Reinforcement Incorporation Method for 3D Printed Concrete using MCDM. Iranian Journal of Science and Technology, Transactions of Civil Engineering 2025; 1-13. DOI: https://doi.org/10.1007/s40996-025-01766-w

Mohamed OA, Masood SH, Bhowmik JL, Nikzad M, Azadmanjiri J. Effect of process parameters on dynamic mechanical performance of FDM PC/ABS printed parts through design of experiment. Journal of Materials Engineering and Performance 2016; 25(7): 2922-2935. DOI: https://doi.org/10.1007/s11665-016-2157-6

Torres J, Cole M, Owji A, DeMastry Z, Gordon AP. An approach for mechanical property optimization of fused deposition modeling with polylactic acid via design of experiments. Rapid Prototyping Journal 2016; 22(2): 387-404. DOI: https://doi.org/10.1108/RPJ-07-2014-0083

Pranata D, Santoso B, Ayuningtyas F. Advancements in Intelligent Design, Simulation Techniques, Technological Safety Innovations, and Sustainable Manufacturing Practices. Transactions on Artificial Intelligence, Machine Learning, and Cognitive Systems 2025; 10(3): 16-29.

Nwaobia NK, Nwasike CN, Tula OA, Umoh AA, Gidiagba JO. Safety protocols in electro-mechanical installations: Understanding the key methodologies for ensuring human and system safety. 2024.