Impact of process parameters and material selection on the mechanical performance of FDM 3D-Printed components

Hybrid Advances Pub Date : 2025-05-13 DOI:10.1016/j.hybadv.2025.100502

Md Mahbub Morshed Haque, Suchinto Roy Dhrubo, Al-Fida Zubayer Pranto, Akash Ahmed, Md Miraj Arefin, Md Arifuzzaman, Md Shariful Islam

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Abstract

Fused Deposition Modelling (FDM) is a widely adopted additive manufacturing technique that constructs objects by sequentially depositing layers of thermoplastic filament. The mechanical performance of FDM-printed components is influenced by both material selection and process parameters, making their optimization crucial for achieving superior print quality and reliability. This study evaluates the mechanical properties of five materials, including conventional polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS), alongside emerging alternatives: carbon fiber-reinforced PLA (PLA-CF), polyethylene terephthalate glycol (PETG), and carbon fiber-reinforced high-temperature nylon (PAHT-CF). Additionally, four key process parameters were varied, and their effects were analyzed using a Taguchi L9 orthogonal Design of Experiments (DOE) approach to minimize experimental runs. ANOVA analysis was employed to determine the statistical significance of process parameters on mechanical performance. Tensile, compressive, and flexural tests revealed that PAHT-CF exhibited superior strength in all categories, while nozzle diameter emerged as the most influential parameter. The fractographic analysis further clarified failure mechanisms, providing insights for optimizing material-process combinations in advanced FDM applications.

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工艺参数和材料选择对FDM 3d打印部件力学性能的影响

熔融沉积建模（FDM）是一种广泛采用的增材制造技术，通过逐层沉积热塑性长丝来构建物体。fdm打印部件的机械性能受到材料选择和工艺参数的影响，因此它们的优化对于实现卓越的打印质量和可靠性至关重要。本研究评估了五种材料的机械性能，包括传统的聚乳酸（PLA）和丙烯腈-丁二烯-苯乙烯（ABS），以及新兴的替代品：碳纤维增强PLA (PLA- cf)，聚对苯二甲酸乙二醇酯（PETG）和碳纤维增强高温尼龙（PAHT-CF）。此外，采用田口L9正交试验设计（DOE）方法分析了4个关键工艺参数的影响，以减少试验次数。采用方差分析确定工艺参数对机械性能的显著性。拉伸、压缩和弯曲试验表明，PAHT-CF在所有类别中都表现出优越的强度，而喷嘴直径是影响最大的参数。断口分析进一步阐明了失效机制，为优化先进FDM应用中的材料-工艺组合提供了见解。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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Hybrid Advances

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