Optimising FDM printing parameters for improved tensile properties in 3D printed ASTM D638 standard samples

Abstract

ABSTRACT The present study aims to optimise Fused Deposition Modelling (FDM) printing parameters to enhance the tensile properties of 3D printed specimens adhering to the ASTM D638 standard. The mechanical integrity of printed components is crucial for their successful application in load-bearing scenarios. Through a systematic exploration of key FDM printing parameters, such as layer height, infill density, print speed, and extrusion temperature, their impact on the tensile strength, yield strength, and elongation at break of the ASTM D638 specimens have been explored. The Taguchi design of experiments methodology has been utilised to efficiently traverse the parameter space and identify the optimal combination of printing settings. Tensile tests were conducted on the 3D printed specimens, produced with different parameter configurations, to evaluate their mechanical performance. The results have been analysed to reveal the significant effects of each parameter on the tensile properties and the interactions between multiple parameters. The optimised parameters identified in this research can be directly implemented to enhance the mechanical performance of 3D printed components in practical applications. Additionally, this work contributes to a broader understanding of the interplay between process parameters and material properties in additive manufacturing, facilitating further advancements in the field. Through rigorous experimentation and optimisation, a suitable range of input parameters was identified to achieve maximum tensile strength. Specifically, the extruder temperature is recommended to be within the range of 207.5°C to 210°C, layer thickness between 0.23 and 0.30 mm, print speed between 40 and 44 mm/sec, and infill density between 94% and 100%.