Influence of process parameters on mechanical properties and surface roughness in fused filament fabrication: a comprehensive review

Fused filament fabrication [FFF] is an extensively used additive manufacturing [AM] technique, owing to the low production cost and availability of materials as compared to other AM techniques. It is evident that the mechanical performance and surface finish of printed parts are notably influenced by the process parameters. Several process parameters are involved in FFF, and the use of optimum parameters is critically important for achieving the desired printing quality. Several researchers tried to comprehend the influence of process parameters in FFF printing; however, a comprehensive examination is still needed to reveal the significance of various process parameters, such as layer height, infill density, printing speed, printing temperature, build orientation, raster angle, and printing pattern, on [i] mechanical properties like tensile, impact, and bending; and [ii] surface roughness. The existing research work has been critically reviewed and analyzed to streamline the process parameters for optimum quality. The optimum range of process parameters for above-mentioned mechanical properties and surface roughness has been abridged in tabulated form, and graphical data are presented to aid in qualitative assessments in FFF printing.