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<p>Fused filament fabrication (FFF) of PA12 nylon is increasingly relevant for functional polymer components, but its industrial use is limited by a narrow processing window, warpage-related detachment, and moisture sensitivity, which can compromise repeatability and mechanical reliability. In this context, the present study investigates how extrusion temperature and layer thickness affect the flexural behavior, mesostructural quality, and process efficiency of FFF-printed nylon. PA12 specimens were manufactured after a preliminary printability assessment aimed at improving build-plate adhesion and controlling filament moisture. A 2 × 5 experimental matrix was defined by combining two extrusion temperatures, 260 and 270&#xa0;°C, with five layer thicknesses, 0.12, 0.16, 0.20, 0.24, and 0.28&#xa0;mm. Flexural properties were evaluated through three-point bending tests, supported by statistical analysis, optical microstructural observations, and a gate-to-gate sustainability assessment including material usage, build time, energy demand, productivity, energy per unit strength, and direct production cost. The results show that extrusion temperature significantly influences flexural performance, with 270&#xa0;°C generally providing higher flexural strength and modulus than 260&#xa0;°C. Layer thickness exhibited a non-monotonic effect, with the 0.24&#xa0;mm / 270&#xa0;°C condition achieving the best mechanical response, corresponding to a flexural strength of approximately 60.48&#xa0;MPa and a more regular bead architecture. Conversely, the 0.20&#xa0;mm / 260&#xa0;°C condition showed the poorest performance, associated with higher mass deviation and visible mesostructural defects. From the sustainability perspective, thicker layers reduced build time and improved productivity, while the best energy-to-performance balance was obtained at 270&#xa0;°C / 0.24&#xa0;mm; however, the direct cost analysis highlighted a trade-off between mechanical optimization and cost minimization. The scientific contribution of this work lies in linking process parameters, mass deviation, mesostructural integrity, flexural performance, and process efficiency, proposing mass deviation as a simple indirect indicator for monitoring consolidation quality in FFF-printed engineering polymers.</p>

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Effect of extrusion temperature and layer thickness on flexural behavior and process sustainability of FFF-printed nylon

  • 期刊论文

  • 发表日期：

    2026年7月21日

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  • Mohamed Chairi,
  • Mariasofia Parisi,
  • Guido Di Bella

摘要

Fused filament fabrication (FFF) of PA12 nylon is increasingly relevant for functional polymer components, but its industrial use is limited by a narrow processing window, warpage-related detachment, and moisture sensitivity, which can compromise repeatability and mechanical reliability. In this context, the present study investigates how extrusion temperature and layer thickness affect the flexural behavior, mesostructural quality, and process efficiency of FFF-printed nylon. PA12 specimens were manufactured after a preliminary printability assessment aimed at improving build-plate adhesion and controlling filament moisture. A 2 × 5 experimental matrix was defined by combining two extrusion temperatures, 260 and 270 °C, with five layer thicknesses, 0.12, 0.16, 0.20, 0.24, and 0.28 mm. Flexural properties were evaluated through three-point bending tests, supported by statistical analysis, optical microstructural observations, and a gate-to-gate sustainability assessment including material usage, build time, energy demand, productivity, energy per unit strength, and direct production cost. The results show that extrusion temperature significantly influences flexural performance, with 270 °C generally providing higher flexural strength and modulus than 260 °C. Layer thickness exhibited a non-monotonic effect, with the 0.24 mm / 270 °C condition achieving the best mechanical response, corresponding to a flexural strength of approximately 60.48 MPa and a more regular bead architecture. Conversely, the 0.20 mm / 260 °C condition showed the poorest performance, associated with higher mass deviation and visible mesostructural defects. From the sustainability perspective, thicker layers reduced build time and improved productivity, while the best energy-to-performance balance was obtained at 270 °C / 0.24 mm; however, the direct cost analysis highlighted a trade-off between mechanical optimization and cost minimization. The scientific contribution of this work lies in linking process parameters, mass deviation, mesostructural integrity, flexural performance, and process efficiency, proposing mass deviation as a simple indirect indicator for monitoring consolidation quality in FFF-printed engineering polymers.