On the quantitative assessment of the effect of multiple process parameters on the printed layer height in 3D inkjet printing

3D inkjet (3D-IJ) printing is recognised for its potential in high-value applications, including printed electronics, tissue engineering and bio-inspired structures, given its precision and ability to deposit multiple materials. The quality of 3D-IJ printed parts is contingent upon meticulous control of the process governing parameters. This study experimentally investigates the influence of various parameters within the 3D-IJ process, i.e., printing resolution, coverage percentage, droplet volume, printing speed and UV-Power and their interaction effects on the printed layer height. The results were analysed statistically using ANOVA and a quadratic regression model was developed to quantitatively identify the relationship between the process response and parameters. Except UV-Power, all parameters, and their interactions with each other had noticeable effects on the printed layer height, with a distinct trend observed for each, affecting the height that ranged from 4.73 mu m to 98.58 mu m. Increasing printing resolution, coverage percentage and droplet volume resulted in an increase in layer height as all three parameters contribute to a larger volume of dispensed material per layer. Printing resolution was found to be the most influential parameter, evidenced by a significant p-value. Finally, the optimal printing parameters for two scenarios, highest printed layer and cost-effective printing were individually identified.