The selection of process parameters is crucial in 3D printing for product manufacturing. These parameters govern the operation of production machinery and influence the mechanical properties, production time, and other aspects of the final product. The optimal process parameter settings vary depending on the product and printing application. This study identifies the most suitable cluster of process parameters for producing rotating components, specifically impellers, using carbon-reinforced Polyether Ether Ketone (CF-PEEK) thermoplastic filament. A mathematical programming technique using a rating method was employed to select the appropriate process parameters. The research concludes that an infill density of 70%, a layer height of 0.15 mm, a printing speed of 60 mm/s, a platform temperature of 195 °C, an extruder temperature of 445 °C, and an extruder travel speed of 95 mm/s are optimal process parameters for manufacturing rotating components using carbon-reinforced PEEK material.

Additive Manufacturing (AM) techniques, such as Fused Deposition Modeling (FDM) and Stereolithography (SLA), are increasingly adopted in various high-demand sectors, including the aerospace, biomedical engineering, and automotive industries, due to their design flexibility and material adaptability. However, the tribological performance and surface integrity of parts manufactured by AM are the biggest functional deployment challenges, especially in wear susceptibility or load-carrying applications. The current review provides a comprehensive overview of the tribological challenges and surface engineering solutions inherent in FDM and SLA processes. The overview begins with a comparative overview of material systems, process mechanics, and failure modes, highlighting prevalent wear mechanisms, such as abrasion, adhesion, fatigue, and delamination. The effect of influential factors (layer thickness, raster direction, infill density, resin curing) on wear behavior and surface integrity is critically evaluated. Novel post-processing techniques, such as vapor smoothing, thermal annealing, laser polishing, and thin-film coating, are discussed for their potential to endow surface durability and reduce friction coefficients. Hybrid manufacturing potential, where subtractive operations (e.g., rolling, peening) are integrated with AM, is highlighted as a path to functionally graded, high-performance surfaces. Further, the review highlights the growing use of finite element modeling, digital twins, and machine learning algorithms for predictive control of tribological performance at AM parts. Through material-level innovations, process optimization, and surface treatment techniques integration, the article provides actionable guidelines for researchers and engineers aiming at performance improvement of FDM and SLA-manufactured parts. Future directions, such as smart tribological, sustainable materials, and AI-based process design, are highlighted to drive the transition of AM from prototyping to end-use applications in high-demand industries.

The integration of sustainable polymers in fused deposition modeling (FDM) 3D printing offers a promising pathway toward reducing the environmental impact of additive manufacturing. However, the energy-intensive nature of FDM processes presents a significant challenge to the overall sustainability of this technology. In this study, we explore the use of bio-based and recycled polymers in FDM printing and develop optimization strategies to reduce energy consumption without compromising material and print performance. Our results demonstrate that by systematically optimizing key printing parameters such as extrusion temperature, print speed, and layer height it is possible to achieve up to 20% energy savings. Additionally, we find that novel material formulations and advanced thermal management techniques enhance the mechanical properties of printed objects by up to 15%, all while minimizing energy use. This research not only advances the field of sustainable 3D printing but also provides a framework for the development of next-generation materials and processes that align with the principles of a circular economy.

This article presents a comprehensive review of advanced techniques for integrating nanomaterials into fused deposition modeling (FDM) processes, addressing prevalent challenges such as limited surface quality and wear resistance in traditional FDM-printed parts. The integration of nanomaterials offers potential solutions to these issues by enhancing surface properties. This review explores key methodologies, including direct nanoparticle mixing with polymer filaments, in-situ polymerization, and surface coating techniques, and demonstrates their impact on improving surface roughness and wear resistance. Specifically, nanomaterial-enhanced composites achieve up to a 30% reduction in surface roughness and a 40% improvement in wear resistance compared to conventional materials. To optimize manufacturing processes, we apply the Taguchi method to identify critical process parameters such as extrusion temperature, print speed, layer thickness, and nanoparticle concentration that influence surface properties. Our simulations and analysis of variance (ANOVA) indicate that optimal settings can enhance surface quality by 25% and improve wear resistance by 35%. The proposed methodologies and theoretical framework lay the groundwork for experimental validation, which will involve testing the optimized parameters and assessing their practical impact. This research advances the field of additive manufacturing by providing novel insights into nanomaterial integration, paving the way for improved FDM technology with applications spanning aerospace, biomedical engineering, and beyond. The findings contribute significantly to overcoming existing limitations and enhancing the performance of FDM-printed parts.

The transition to sustainable polymers is crucial for reducing the environmental footprint of additive manufacturing, particularly in fused deposition modeling (FDM). This study investigates surface metamorphosis techniques—methods to modify polymer surfaces at micro and nanoscale levels to enhance performance and minimize environmental impact. We explore plasma treatment, chemical etching, and laser texturing on biodegradable and recycled polymers, assessing their effects on surface properties, such as adhesion, roughness, and chemical resistance. Our results demonstrate significant enhancements in mechanical properties. For example, PLA’s tensile strength increased from 55.3 MPa (untreated) to 63.8 MPa (plasma treated), and its elongation improved from 4.2% to 5.1%. PHA showed a similar trend, with tensile strength rising from 45.1 MPa to 52.6 MPa, and elongation increasing from 5.6% to 6.4%. rPET and rPP also exhibited improvements, indicating the effectiveness of these surface treatments. Employing a multi-criteria decision-making approach, we assess and prioritize these techniques based on their mechanical enhancements and sustainability profiles. While this study presents hypothetical results, it establishes a comprehensive framework for optimizing surface metamorphosis processes, guiding future experimental research. Our findings suggest that tailored surface modifications can significantly improve the performance and environmental sustainability of polymers in FDM, offering pathways for integrating eco-friendly materials into advanced manufacturing. This work contributes to the development of green manufacturing technologies by highlighting surface metamorphosis as a key strategy for achieving high-performance and sustainable materials.

The development of sustainable polymers is critical to the progression of greener manufacturing processes, especially for the additive manufacturing technologies of fused deposition modeling (FDM). The study aims to explore potential application surface engineering techniques that enhance the performance of these sustainable polymers within the context of FDM. Various surface modification methods, such as plasma treatment, chemical etching, and UV irradiation, were utilized on biodegradable and recycled polymers, with the treatment process conducted under controlled conditions. Mechanical testing was done using a Tinius Olsen universal testing machine, with surface morphology analyzed through scanning electron microscopy. The outcome indicated that the tensile strength of polylactic acid improved by 15% with plasma treatment, while the thermal stability of recycled polyethylene terephthalate improved by 12% with chemical etching. Surface engineering developments on various techniques will be reviewed, particularly in optimizing them within FDM processes for different types of polymers. Different surface modifications will be compared here, analyzing aspects such as adhesion, endurance, and more overall performance. This comparison provides a fundamental outlook into the relationship between surface treatment and polymer performance, paving the way for optimization of FDM processes in sustaining material applications. These findings serve as further guidance toward making additive manufacturing much more sustainable and efficient through advanced surface engineering. The numerical improvement of material properties observed in the study will aid in further endeavors towards achieving sustainability and efficiency in additive manufacturing.