The influence of Material Extrusion process parameters on the porosity and mechanical properties of PLA products for medical applications

Abstract

Purpose The study addresses the growing need for personalized medicine and cost-effective manufacturing by investigating additive manufacturing (AM). It employs the Design of Experiments (DOE) to explore how fused filament fabrication (FFF) parameters affect porosity and mechanical properties of medical-grade polylactide (PLA) samples. Methods Various PLA build configurations were fabricated and assessed using computed tomography (CT) scans for internal geometry and porosity. Compression tests were conducted to determine compressive strength, deformation, and Young's modulus. A comprehensive statistical analysis, utilizing three-way ANOVA, was carried out to establish the relationships between the process parameters and the obtained results. Results The study reveals the impact of FFF process parameters (layer thickness, wall thickness, and infill density) on porosity and mechanical properties. Computed tomography analysis confirmed internal geometry and porosity, while compression tests provided insights into compressive strength, deformation, and Young's modulus. Conclusions Optimal process parameters for desired mechanical properties and porosity in PLA models are highlighted, contributing to advanced medical applications. Informed FFF process parameter utilization enhances the potential for personalized therapeutic solutions and cost-effective pharmaceutical manufacturing.