Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

journal homepage: www.elsevier.com/locate/matpr

Multi-objective optimization of 3D Printing process using genetic

algorithm for fabrication of copper reinforced ABS parts
Balwant Singh, Raman Kumar, Jasgurpreet Singh Chohan ⇑
Department of Mechanical Engineering, Chandigarh University, Mohali, 140413, India

a r t i c l e i n f o a b s t r a c t

Article history: Fused deposition modeling (FDM) is now used in various industries to create functional parts using poly-
Received 7 May 2021 mers and metal reinforced polymer composites to attain desired properties. This study has been per-
Received in revised form 14 June 2021 formed to acquire best FDM process parameters for maximization of tensile strength, compressive
Accepted 17 June 2021
strength, and flexural strength. Copper particle reinforced ABS filament is used for fabrication of test sam-
Available online xxxx
ples to highlight the applications of 3d printing in composites. Multi-objective optimization has been per-
formed using genetic algorithm to optimize three input parameters of FDM i.e. printing temperature,
Keywords:
infill pattern, and layer height. The mechanical properties were calculated through Taguchi L9 design
Multi-objective optimization
ABS
of experiments approach. It has been noticed that there was conflicting effect of each FDM parameter
Copper particles on strength. By using a genetic algorithm, the parameters are optimized and hence single combination
FDM was achieved i.e. 244.90 °C printing temperature, 0.20 mm layer height, and zig-zag pattern. The study
Genetic algorithm would be helpful to fabricate copper reinforced ABS components for electronics, automobile and aero-
space industry.
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Symposium on Synth-
esis, Characterization 2021.

1. Introduction
In comparison to traditional approaches, additive manufactur-
ing (AM) is a technique which is used to produce components with
complex geometry in less time and without the use of tooling. AM
technologies are well-known for their flexibility in production,
which is required in new product development to manufacture
the product within short product life cycle and quick cycle time
[1]. After stereo-lithography, the FDM method is the second most
prevalent AM technology. It is popular because of its quick cycle
time, high dimensional precision, desktop capability, and safety.
It may also be easily integrated with a variety of CAD programs.
Due to developments in system configuration and filament materi-
als, the technology is gaining popularity by the day. Optimizing the
process parameters can increase the accuracy and efficiency of
FDM parts even more [2]. Despite the fact that FDM is a widely uti-
lized and effective method, it has restricted uses due to its compat-
ibility with only specified materials. This constraint can be
resolved by developing new materials that are compatible with
⇑ Corresponding author.
E-mail address: jasgurpreet.me@cumail.in (J. Singh Chohan).
technology and have better properties than the commercial grades
of acrylonitrile butadiene styrene (ABS) material that are most
commonly used in FDM [3]. To improve the mechanical properties
copper particles were used with ABS thermoplastics in the present
work but the 3D printing of ABS and Copper particles facing many
issues while the selection of manufacturing parameters [4,5].
Boparai et al. [6] highlight the advantages of fiber reinforced poly-
mer materials for rapid prototyping and Biomaterials for implant
manufacturing are also emphasized in this study. It has been con-
cluded that he thermal, mechanical, and morphological qualities of
FDM prints are improved by using fibre reinforced polymers in a
matrix material. Bio steel is a genetic spider silk-based high-
strength fibre-based material. It is also suited for a variety of med-
ical applications due to its light density, superior mechanical qual-
ities, and increased temperature stability (-4°C to 250 °C). Food
containers with nano-materials and bio-based materials have bet-
ter mechanical, antibacterial, and anti-oxidant capabilities. How-
ever, continuous efforts are needed to produce biodegradable
feedstock filament materials for custom applications. Asadi-
Eydivand et al. [7] completed research by using Aggregated Artifi-
cial Neural Network (AANN) to measure the impact of thickness of
layer, the duration during distributing layer of polymers while

https://doi.org/10.1016/j.matpr.2021.06.264
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Symposium on Synthesis, Characterization 2021.

Please cite this article as: B. Singh, R. Kumar and J. Singh Chohan, Multi-objective optimization of 3D Printing process using genetic algorithm for fabri-
cation of copper reinforced ABS parts, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2021.06.264
B. Singh, R. Kumar and J. Singh Chohan Materials Today: Proceedings xxx (xxxx) xxx

printing, as well as the printing angle of structures which were algorithm to find out the best combination of parameters to
porous and directly affect the compressive strength of scaffolds. achieve better results.
To achieve the best 3D printing parameter settings, two optimiza-
tion algorithms were used. To begin, a swarm particle optimization
2. Experimental methods
method was used to determine the AANN’s optimal topography.
The optimum design variables for the manufacturing of the scaf-
In the present study, first of all, the material selection was done
folds with the necessary compressive strength and pore volume
for the formation of feedstock filament by using different composi-
were then determined using Pareto front optimization. The find-
tions. After the manufacturing of feedstock filament, the input
ings show that evolutionary strategies have a reasonable chance
parameters were selected for the FDM process and the specimens
of managing and optimizing the 3D printing process as a complex
were manufactured for tensile, compressive, and flexural testing
engineering issue. Boparai et al. [8] done investigation for grinding
with the help 3D printer. Once, the specimens were manufactured
applications, to improve the wear qualities of rapid tooling (RT) by
the testing of each specimen or bars was done by using Universal
reinforcing fillers (nanoscaled). For the improvement of grinding
Testing Machine and the output readings were recorded. By using
wheels with custom designed wear-resistant characteristics, rapid
the Minitab software, the analysis was done to find out the best
tooling was created utilizing biocompatible composite material
optimal parameter combinations to find out the best output
(BCCM) feed stock filament (comprised of Nylon 6 as a binding
results. After this optimization, Genetic Algorithm optimization
material, strengthened with biocompatible nanoscale Aluminium
was done to obtain the best combination of input parameters for
oxide particles) on fused deposition modeling (FDM). It has been
achieving the optimal output readings in tensile, flexural, and com-
observed that because of the inclusion of nanoscaled Aluminium
pressive testing. Fig. 1 represents the methodology of the present
oxide particles in the Nylon 6 matrix, the RT made from BCCM is
study.
more wear resistant. Abrasive wear is the dominant mechanism
ABS and 10% Copper particles (200 Mesh) are used to prepare
in the situation of RT made of ABS plastic. In the case of BCCM,
composite filament. The feedstock filament was manufactured by
however, wear is mostly caused by adhesion. Where contrasted
using the twin-screw extruder. The twin-screw extruder (supplied
to ABS material (when the load applied is 20 N, running with a fre-
by ThermoFisher Scientific, USA) was running on 85 rotational per
quency of 0.63 m/s for 10 min), the BCCM has a lower coefficient of
minute speed while maintaining the nozzle temperature at 230 0C.
friction (49%) and friction coefficient (49%) as well as reduced wear
The spool was used at front of a twin-screw extruder machine to
(94%) and material loss (96%). The BCCM shows a modest temper-
collect the feedstock filament which was manufactured on the
ature variation as test conditions vary, indicating the material’s
machine. Thermo fisher company twin-screw extruder was used
strong rigidity and stability. The wear tracks show that RT depend-
during present research work. The twin extruder has been shown
ing on BCCM is much more resistant to wear. Furthermore, com-
in Fig. 2(a). Afterwards, by using the 3D printer, 9 parts were man-
pared to ABS, it is more thermostable and stiffer. Boparai et al.
ufactured for each testing such as tensile, compressive, and flexural
[2] completed their research by using response surface methodol-
bars. The Taguchi L9 orthogonal array was prepared by using mini
ogy. A comprehensive research into the manufacturing of Nylon6–
tab software. The 3D printer has been shown in Fig. 2(b) and (c)
Al–Al2O3-based alternative fused deposition modeling process
shows the specimens used for mechanical testing.
(FDM) feedstock filament (in favour of commercial acrylonitrile
The Universal Testing Machine (supplied by Shanta Engineering
butadiene styrene filament) by optimizing the parameters of a
Pvt. Ltd., Pune, India) was used to test all 27 specimens. The output
single-screw extruder in aspects of responses (elastic modulus
results obtained after the testing for the tensile, compressive, and
and circumference deviation). The adjustment of primary input
flexural bars noted. Fig. 3 shows the testing which was done for
parameters as during manufacturing of alternative material on a
the tensile, compressive, and flexural test.
single-screw extruder has a substantial impact on the tensile
strength of feedstock filament. For the response regression models,
multi-objective and multi-response simulation techniques are 3. Results and discussions
based on the use of desirability idea were used to concurrently
identify a combination of appropriate input variables, producing The results were obtained after tensile, compressive, and flexu-
the higher tensile strength as well as the lowest possible variance ral testing done by using Universal Testing Machine. The maximum
in feedstock filament diameter. The experimental results for both
responses at the best combination of analytical screw extruder
parameters are supported by anticipated values and a 5% error
margin when compared to experimental values. Because so many
parameters can influence the manufacturing process, the manufac-
turer’s guiding principle of manufacturing operating conditions
cannot assure the accuracy of printed goods [9]. Incorrect parame-
ters of printing setup will lead to excessive time, excess weight,
and poor tensile properties, raising manufacturing costs, wastes
generated and having difficulties for specific users to manufacture
the 3D parts [10]. The selection of the best suitable parameter is
the basic requirement for any process which can be done by vari-
ous optimization techniques. In the present study, ABS polymers
were mixed up with Copper particles (200 Mesh) to manufacture
the 3D printing parts. The Input parameters were selected as Print-
ing Temperature, Layer height, and Infill Pattern according to the
L9 Orthogonal Array Taguchi Method, and the Output Parameters
were Tensile, Compressive, and Flexural Properties of 3D Printing
Parts. After finding the Mechanical properties of 3D printing parts
the Multi-Objective Optimization was done by using genetic Fig. 1. Step-by-step procedure adopted during present study.

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B. Singh, R. Kumar and J. Singh Chohan
Fig. 2. (a) Twin Screw Extrusion Machine, (b) 3D Printing Machine, (c) Tensile, Compressive and Flexural test samples.
Fig. 3. (a) Tensile Testing, (b) Compressive Testing, (c) Flexural Testing Specimens in Universal Testing Machine.
and minimum Ultimate Tensile Strength was obtained as 941.4 N
and 278 N respectively in which the bars having the highest tensile
strength manufactured with input parameters 240 °C Printing
Temperature, 0.10 mm Layer height, and Zig-Zag Infill Pattern
whereas the bars achieved lowest tensile strength manufactured
with 230 °C Printing Temperature, 0.20 mm Layer height, and Tri-
angle Pattern. The maximum and minimum Ultimate Compressive
Strength was achieved as 4435.2 N and 1237.6 N respectively for
the specimens which were manufactured with input parameters
for highest compressive strength was 250 °C Printing Temperature,
0.20 mm Layer height, and Zig-Zag Pattern. On the other hand,
input parameters for lowest compressive strength were 230 °C
Printing Temperature, 0.20 mm Layer height, and Triangular Infill
Pattern. In the Flexural testing, the maximum Ultimate Flexural
Strength was obtained as 171.6 N and the minimum flexural
strength was 51.4 N. The input parameters selected for highest
flexural strength was taken as Printing Temperature 240 °C, Layer
Height 0.10 mm and the Infill Zig-Zag and the minimum flexural
strength was obtained at Printing Temperature 230 °C, Layer
Height 0.20 mm and the Infill Pattern Triangles was used for man-
ufacturing the parts. Table 1 shows the results obtained after test-
ing done on Universal Testing Machine.
It can be noticed that ultimate tensile strength is maximum in
Experiment no. 4 whereas ultimate flexural strength is maximum
in experiment no. 5. During compressive strength measurements,
the maximum value was obtained at Experiment no. 9. Hence, it
difficult to attain maximized values of all these three types of
strengths. There is need to attain single parametric settings which
3
Materials Today: Proceedings xxx (xxxx) xxx
would yield maximized strength of composite parts in terms of
flexural, tensile and compressive strength. The multi-objective
optimization must be implemented to acquire these settings.
4. Multi- objective optimization by using genetic algorithm
method
Multi-objective optimization problems of complex manufactur-
ing systems are not easy tp solve using conventional tools [11]. In
the present research to find out the best combination of input
parameters for better output results, one of several basic
random-based Evolutionary Algorithms was used named as
Genetic algorithm (GA). In the present optimization, X1 name
was determined to Printing Temperature, Layer Height named as
X2 and Infill Pattern named as X3. So, by using regression analysis
the three equations were formed for finding the ultimate tensile
strength (1), ultimate flexural strength (2) and ultimate compres-
sive strength (3).
Ultimate Tensile Strength ¼ UTSMAX
¼ 58676 þ 458:4 X1
þ 23638 X2 þ 1409 X3
 0:8622 X1  X1
þ 12980 X2  X2  25:80 X3
 X3  135:9 X1  X2
 5:593 X1  X3 ð1Þ
B. Singh, R. Kumar and J. Singh Chohan Materials Today: Proceedings xxx (xxxx) xxx

Table 1
Input and output parameters.

Experiment no. Printing Temperature (0C) Layer Height (mm) Infill Pattern Ultimate Tensile Ultimate Flexural Ultimate Compressive
Strength (N) Strength (N) Strength (N)
1 230 0.1 Lines (1) 611.9 99 4425.4
2 230 0.15 Zig-Zag (2) 438.3 119.1 3475.1
3 230 0.2 Triangles (3) 278 51.4 1237.6
4 240 0.1 Zig-Zag (2) 941.4 171.6 3775.6
5 240 0.15 Triangles (3) 592.3 154.4 3966.4
6 240 0.2 Lines (1) 442.7 135.8 4231.7
7 250 0.1 Triangles (3) 935 163.7 1448.9
8 250 0.15 Lines (1) 764.4 124 2171.7
9 250 0.2 Zig-Zag (2) 407.9 123.5 4435.2

Table 2
Optimization Results for single and multi-objective optimization.

S. No. Optimization Notation Printing Temperature in 0C (X1) Layer height in mm (X2) Infill Pattern (X3) Objective Function Value
1 Single Objective UTSMAX 250.00 0.10 Lines 1117.55
2 Single Objective UFSMAX 243.80 0.13 Zig-Zag 196.24
3 Single Objective UCSMAX 245.67 0.20 Zig-Zag 4513.78
4 Multi- Objective ZMIN 244.90 0.20 Zig-Zag 1694.10

Ultimate Flexural Strength ¼ UFSMAX Ultimate Compressive Strength ¼ UCSMAX

¼ 23798 þ 196:1 X1
þ 8931 X2  483:4 X3
 0:4048 X1  X1
 8107 X2  X2  23:63 X3
 X3  27:80 X1  X2
þ 2:387 X1  X3
¼ 524830 þ 4886 X1  547134 X2  14371 X3
 11:26 X1  X1  109520 X2  X2  369:8 X3  X3
þ 2448 X1  X2 þ 65:69 X1  X3 ð3Þ
In this research, the requirement was maximum output results
for which the above given three equations were formed by using a
genetic algorithm.
ð2Þ

Fig. 4. Optimization Graphs.

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B. Singh, R. Kumar and J. Singh Chohan Materials Today: Proceedings xxx (xxxx) xxx

Fig. 5. Three Dimensional graphs in between Layer Height and Printing temperature with (a) Ultimate Tensile Strength, (b) Ultimate Compressive Strength, and (c) Ultimate
Flexural Strength.

After using the above equations, it has been concluded that the (196.24 N) was achieved by using 244 °C (Printing Temperature),
Maximum Ultimate Tensile Strength (1117.5 N) was obtained by 0.13 mm (Layer height), and Zig-Zag (Infill Pattern). Thirdly, it
using the 250 °C (Printing Temperature), 0.10 mm (Layer height), has been assumed that the Maximum Compressive Strength
and Lines (Infill Pattern). Secondly, the Maximum Flexural Strength (4513.78 N) was obtained by using 245.67 0C (Printing

5
B. Singh, R. Kumar and J. Singh Chohan Materials Today: Proceedings xxx (xxxx) xxx

Fig. 6. Three Dimensional graphs in between Layer Height and Infill Pattern with (a) Ultimate Tensile Strength, (b) Ultimate Compressive Strength, and (c) Ultimate Flexural
Strength.

Temperature), 0.20 mm (Layer height), and Zig-Zag (Infill Pattern). output results but if we have to find out the common combination
These combinations were used to find out the individual maximum of input parameters that give maximum output, the genetic

6
B. Singh, R. Kumar and J. Singh Chohan Materials Today: Proceedings xxx (xxxx) xxx

Fig. 7. Three Dimensional graphs in between Printing Temperature and Infill Pattern with (a) Ultimate Tensile Strength, (b) Ultimate Compressive Strength, and (c) Ultimate
Flexural Strength.

algorithm was used as a multi-objective optimization. Eq. (4) was Multi-objective optimization = ZMAX = W1 * (-58676 + 458.4 * X
used to find out the multi-objective optimization according to the (1) + 23638 * X(2) + 1409 * X(3)  0.8622 * X(1)*X(1) + 12980 * X
weight set formula. (2)*X(2)  25.80 * X(3)*X(3)- 135.9 * X(1)*X(2)  5.593 * X(1)*X

7
B. Singh, R. Kumar and J. Singh Chohan
(3)) + W2* (-23798 + 196.1 * X(1) + 8931 * X(2)  483.4 * X(3)
 0.4048 * X(1)*X(1)  8107 * X(2)*X(2)  23.63 * X(3)*X(3)
 27.80 *X(1)*X(2) + 2.387 *X(1)*X(3)) + W3 * (-524830 + 4886 *X
(1)  547134 *X(2)  14371 *X(3)  11.26 *X(1)*X(1)  109520 *X
(2)*X(2)  369.8 *X(3)*X(3) + 2448 *X(1)*X(2) + 65.69 *X(1)*X(3))
(4)
From the above-given equation, the maximum output results
have been obtained by using the input parameters combination
as a 244.90 0C (Printing Temperature), 0.20 mm (Layer height),
and Zig-Zag (Infill Pattern). The Table 2 represents the optimization
results.
The best and mean fitness value has been obtained as 1694.1 N
and 1694.08 N, best worst and mean scores after the optimization
and function selection has been shown in the Fig. 4.
The 3D graphs have been showing according to the weight set
distribution formula for different combinations of input parame-
ters with output results. Fig. 5 shows the three-dimensional graphs
in the relationship between the Layer Height (LH) and Printing
temperature (PT) with Ultimate Tensile Strength (UTS), Ultimate
Compressive Strength (UCS), and Ultimate Flexural Strength
(UFS). Fig. 5(a), it represents that when the maximum tensile
strength can be obtained by having 250 °C Printing Temperature,
and 0.10 mm Layer height. The maximum compressive strength
was achieved with 245.67 0C (Printing Temperature), 0.20 mm
Layer height as shown in Fig. 5(b). Lastly, the maximum flexural
strength was obtained with a combination of 244 °C Printing Tem-
perature, and 0.13 mm Layer height as shown in Fig. 5(c).
Fig. 6 represents the three-dimensional graph in between the
Layer Height and Infill Pattern with Ultimate Tensile Strength, Ulti-
mate Compressive Strength, and Ultimate Flexural Strength. It has
been analyzed that the maximum tensile strength was obtained
with 0.10 mm Layer height, and Lines Pattern as represents in
Fig. 6(a), whereas the ultimate compressive strength was achieved
at 0.20 mm Layer height, and Zig-Zag Infill Pattern as shown in
Fig. 6(b). Finally, in Fig. 6(c) the ultimate flexural strength was
obtained with the combination of 0.13 mm Layer height, and Zig-
Zag Pattern.
Fig. 7 shows the relationship through a three-dimensional
graph in between the Printing Temperature and Infill Pattern with
Ultimate Tensile Strength, Ultimate Compressive Strength, and
Ultimate Flexural Strength. Fig. 7(a) represents that the maximum
ultimate tensile strength was achieved with a combination of
250 °C Printing Temperature, and Lines Pattern, whereas from
Fig. 7(b), the ultimate compressive strength was achieved with a
combination of 245.67 0C Printing Temperature, and Zig-Zag Pat-
tern and lastly from the Fig. 7(c) the best combination was
244 °C Printing Temperature, and Zig-Zag Pattern.
In future, different compositions of materials can be manufac-
tured by checking their melt flow rate. Various other properties
can be checked before the manufacturing of feedstock filament
from a twin-screw extruder machine. The feedstock filament can
be manufactured at a different range of temperatures and rota-
tional speed of screw extruders. The feedstock filament can be
manufactured at a different range of temperatures and rotational
speed of screw extruders. Also, different optimization techniques
can also be used to check out the best output results. The different
output properties can be checked as per the requirements. Only
three FDM process parameters have been investigated, even
though other parameters may also affect the output properties.
Only mechanical properties have been considered, even though
there are a variety of other properties that could be investigated.
Materials Today: Proceedings xxx (xxxx) xxx
5. Conclusions
The FDM process parameters are optimized using multi-
objective optimization to maximize the mechanical strength of
copper reinforced ABS composite parts. In the present research, it
has been found that Genetic Algorithm is an efficient tool for per-
forming multi-objective optimization of complex problems of FDM
process. The FDM specimens which were manufactured by using
Taguchi L9 Orthogonal Array at input parameters showed huge
variation in output in terms of mechanical strength. The highest
tensile strength was obtained at 250 °C Printing Temperature,
0.1 mm Layer Height and Lines Pattern. The highest compressive
strength was achieved with a combination of 240 °C Printing Tem-
perature, 0.15 mm Layer Height and Zig-Zag Pattern. On the other
hand, maximum flexural strength was attained at 240 °C (Printing
Temperature, 0.1 mm Layer Height and Zig-Zag Infill Pattern. Since
it is difficult to attain best values of each parameter in a single part,
Genetic algorithm was used to attain single set of parameters. An
objective value of 1694.10 was achieved at multi-objective opti-
mization mode which suggested 244.90 °C printing temperature,
0.20 mm Layer Height and Zig-Zag Pattern.
CRediT authorship contribution statement
Balwant Singh: Investigation, Writing - original draft. Raman
Kumar: Writing - review & editing, Project administration. Jasgur-
preet Singh Chohan: Conceptualization, Methodology.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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