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<p>This study investigates the effects of raster angle (0°, 45°, 90°) and infill percentage (25%, 50%, 75%, 100%) on the flexural and thermomechanical behavior of polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) parts fabricated via fused deposition modeling (FDM). A total of 24 parameter sets (12 per material) were 3D printed, with three samples per set (n = 72). Flexural testing and dynamic mechanical analysis (DMA) were conducted to assess the impact of print settings. PLA samples exhibited optimal flexural strength (167.72&#xa0;MPa) at a 0° raster angle and 50% infill, while ABS achieved its highest strength (125.92&#xa0;MPa) at a 0° raster angle and 75% infill. At a 90° raster angle, flexural strength decreased by over 40% for both materials, indicating significant anisotropy. DMA results revealed increased storage modulus (PLA: 3641&#xa0;MPa; ABS: 2330&#xa0;MPa) and loss modulus (PLA: 284&#xa0;MPa; ABS: 163&#xa0;MPa) at a 0° raster angle and 75% infill. Scanning electron microscopy (SEM) fractography showed brittle fracture patterns and layer separation in PLA, while ABS displayed voids and interlayer weaknesses contributing to failure. Raster orientation had a greater influence on flexural strength, whereas infill percentage more significantly affected thermomechanical behavior. These findings establish a process–structure–property framework for optimizing FDM parameters to enhance mechanical performance. The results support the development of high-performance thermoplastic components for automotive and aerospace applications and provide a foundation for extending optimization strategies to reinforced polymer composites.</p>

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Evaluating Mechanical Integrity of 3D-Printed PLA and ABS by Varying Process Parameters

  • 期刊论文

  • 发表日期：

    2025年8月21日

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  • Habeeb Talha Shahan,
  • Shaik Zainuddin,
  • Richard Harry,
  • Zahid Baig,
  • Ghulam Mohammed Sayeed

摘要

This study investigates the effects of raster angle (0°, 45°, 90°) and infill percentage (25%, 50%, 75%, 100%) on the flexural and thermomechanical behavior of polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) parts fabricated via fused deposition modeling (FDM). A total of 24 parameter sets (12 per material) were 3D printed, with three samples per set (n = 72). Flexural testing and dynamic mechanical analysis (DMA) were conducted to assess the impact of print settings. PLA samples exhibited optimal flexural strength (167.72 MPa) at a 0° raster angle and 50% infill, while ABS achieved its highest strength (125.92 MPa) at a 0° raster angle and 75% infill. At a 90° raster angle, flexural strength decreased by over 40% for both materials, indicating significant anisotropy. DMA results revealed increased storage modulus (PLA: 3641 MPa; ABS: 2330 MPa) and loss modulus (PLA: 284 MPa; ABS: 163 MPa) at a 0° raster angle and 75% infill. Scanning electron microscopy (SEM) fractography showed brittle fracture patterns and layer separation in PLA, while ABS displayed voids and interlayer weaknesses contributing to failure. Raster orientation had a greater influence on flexural strength, whereas infill percentage more significantly affected thermomechanical behavior. These findings establish a process–structure–property framework for optimizing FDM parameters to enhance mechanical performance. The results support the development of high-performance thermoplastic components for automotive and aerospace applications and provide a foundation for extending optimization strategies to reinforced polymer composites.