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Additive manufacturing (AM), commonly known as 3D printing, has gained significant popularity for its ability to produce intricate parts with high precision. However, the presence of residual stresses and warpage deformation are common issues affecting the quality and functionality of 3D-printed parts. This study conducts a comprehensive finite element analysis (FEA) to investigate the material-dependent impact of key printing parameters on residual stress and warpage deformation in 3D printing. The research focuses on three distinct materials: polyetherimide (PEI), acrylonitrile butadiene styrene (ABS), and polyamide 6 (PA6). Various printing parameters are systematically varied, including printing temperature, printing speed, bed temperature, infill density, layer thickness, and infill pattern. The study employs the Taguchi L27 orthogonal array and employs the analysis of variance (ANOVA) statistical technique to assess the significance of the input parameters. The obtained results reveal that certain parameters exhibit a greater sensitivity to material differences, whereas the layer thickness parameter demonstrates a relatively lower sensitivity. Notably, infill density and printing temperature play a crucial role in reducing residual stress for PA6, while the infill pattern parameter proves to be a significant contributor to minimizing warpage deformation across all three materials. These findings underscore the importance of conducting material-specific analyses to optimize 3D printing parameters and achieve the desired quality outcomes while mitigating residual stress and warpage deformation. [ABSTRACT FROM AUTHOR]

The evaluation of residual stress is crucial since it has a significant impact on the component's lifetime and can cause breakdown or failure during manufacture, which may affect the economics, lives, and the environment. Residual stress analysis has now become a mandatory requirement in the automobile industry. Because each manufacturing process like machining, casting, heat treatment, and coating impacts the residual stress state, it can be pretty complicated and varied within the components. If the effects of these processes are well studied, it is possible to achieve a stress state in the part that will increase its lifetime and performance while lowering costs with an optimized method. This paper discusses the effect of residual stress on the automotive industry and illustrates how is residual stress participates in every manufacturing process of vehicles. [ABSTRACT FROM AUTHOR]

Fused Filament Fabrication (FFF) is an additive manufacturing technology that is used to create a wide range of parts and applications. Along with its benefits, there are some challenges regarding the printed parts' mechanical properties, which are associated with printing parameters like layer thickness, infill density, print speed, and nozzle temperature. Experimentally investigation of these pamperers is costly and time-consuming. Some simulations are available to use the numerical solution in the investigation. This work used Digimat-AM simulation to investigate the effect of layer thickness on the residual stress and warping deformation of printed ABS parts. [ABSTRACT FROM AUTHOR]