Publication Date


Document Type


Committee Members

Joy Gockel (Advisor), Nathan Klingbeil (Committee Member), Joshua Deaton (Committee Member)

Degree Name

Master of Science in Mechanical Engineering (MSME)


Currently many components are additively manufactured via fused deposition modeling (FDM). However, FDM results in gaps between passes which produces a poor surface finish and porous material that is difficult to hold pressure. Commercial scale air systems require a pressure to be maintained within thin walled components with minimal post processing and clean up after fabrication. A design of experiments (DOE) was created to identify the optimal raster vs contour ratio for UTLEM 9085 CG fabricated using FDM at different build angles and wall thicknesses. A custom-built pressurized test system was developed, the leak rates were calculated and the surfaces were analyzed microscopically. In addition, a statistical analysis was performed at a 95% confidence interval to identify the range of leak rates that could be expected at each thickness and build angle. Results can be used to optimize the FDM process and component geometries for pressurized applications.

Page Count


Department or Program

Department of Mechanical and Materials Engineering

Year Degree Awarded