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

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.