Optimization Fused Deposition Modeling Parameter of Interference Screw using Full Factorial Design

Interference screws are one of the most common and widely used fixing techniques in anterior cruciate ligament (ACL) reconstruction. Fused Deposition Modeling (FDM) is one of the most commonly used methods in additive manufacturing engineering that can be used to manufacture interference screws. Setting the process parameters of FDM for each material used significantly impacts the quality of the product. This paper aims to investigate and optimize the process factors of FDM most affecting interference screw density and torsion. The effect of process factors, including nozzle temperature, layer height, nozzle diameter, print speed, and infill percentage on the interference screw, was calculated statistically by the full factorial design (FFD) design process. The optimized FDM process parameter was a nozzle temperature of 195 °C, a layer height of 0.12 mm, a nozzle diameter of 0.4 mm, a print speed of 40 mm/s, and an infill percentage of 25%. The results supported by statistical analysis can help future research on designing and manufacturing interference screws.