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Abstract Additive manufacturing, an innovative process that assembles materials layer by layer from 3D model data, is recognized as a transformative technology across diverse industries. Researchers have extensively investigated the impact of various printing parameters of 3D printing machines, such as printing speed, nozzle temperature, and infill, on the mechanical properties of printed objects. Specifically, this study focuses on applying Finite Element Analysis (FEA) in G code modification in Fused Deposition Modeling (FDM) 3D Printing. FDM involves extruding a thermoplastic filament in layers over a build plate to create a three-dimensional object. In the realm of load-bearing structures, the Finite Element Analysis (FEA) process is initiated on the target object, employing the primary load to identify areas with high-stress concentrations. Subsequently, optimization techniques are used to strategically assign printing parameter combinations to improve mechanical properties in potentially vulnerable regions. The ultimate objective is to tailor the G code, a set of instructions for the printer, to strengthen particular areas and improve the printed object’s overall structural integrity. To evaluate the suggested methodology’s efficacy, the study conducts a comprehensive analysis of printed objects, both with and without the optimized G code. Simultaneously, mechanical testing, such as tensile testing, demonstrates quantitative data on structural performance. This comprehensive analysis aims to identify the impact of G code alteration on the finished product. Preliminary experimental results using simple tensile specimens indicate notable improvements in structural performance. Importantly, these improvements are achieved without any discernible mass increase, optimizing material usage and reducing the cost of additive manufacturing. The modified G code targets to strengthen critical areas using updated printing parameters without a net increase in the overall material consumption of the object. This finding holds significant implications for industries reliant on additive manufacturing for load-bearing components, offering a promising avenue for improved efficiency and durability. Integrating advanced techniques, such as G code modification and finite element analysis (FEA), as the additive manufacturing landscape evolves presents a pathway toward optimizing mechanical properties. By contributing valuable insights and laying the groundwork for further exploration and refinement of these methodologies, this study paves the way for enhanced structural performance in various additive manufacturing applications. Ultimately, it encourages innovation and progress in the field, propelling the industry toward new heights of efficiency and reliability. 

Abstract Fused deposition modeling (FMD) is considered one of the most common additive manufacturing methods for creating prototypes and small functional parts. Many researchers have studied Polylactic acid (PLA), Polycarbonate (PC), and Acrylonitrile butadiene styrene (ABS) as a material for fused deposition modeling printing. Among them, Polylactic Acid (PLA) is considered one of the most popular thermoplastic materials due to its low cost and biodegradable properties. In this study, silk PLA material was used. In Fused deposition modeling (FMD), the selection of printing parameters plays a pivotal role in determining the overall quality and integrity of the 3D-printed products. These parameters significantly influence the quality and strength of 3-D printed products. This study investigates the mechanical properties of silk-PLA printed specimens under different printing conditions, such as layer thickness, nozzle temperature, and print speed. All the tensile specimens were tested using ASTM D638 to characterize Young’s modulus and ultimate tensile strength. The thickness of the layers of tensile specimens was set to 0.1 mm, 0.15 mm, and 0.2 mm. The temperatures of the nozzle used during printing varied from 200°C, 210°C, and 220°C, whereas print speeds of 100 mm/s, 120 mm/s, and 140 mm/s were considered. The other printing parameters were kept consistent for all specimens. The result indicates tensile strength generally increases with increasing temperature of the nozzle, up to 220°C; however, a decline was observed in the average Young’s modulus value when the thickness of the layer increased from 0.10 mm to 0.20 mm. According to the results of the ANOVA analysis, the interaction between layer thickness, nozzle temperature, and printing speed significantly affects the tensile strength and Young’s modulus of Silk-PLA. This study reveals that nozzle temperature is the most critical parameter regarding the ultimate tensile strength and Young’s modulus, providing crucial insights for optimizing 3D printing parameters.