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<p>Polylactic acid (PLA) is a biodegradable polymer that serves as the principal feedstock in fused deposition modeling (FDM), yet its intrinsic brittleness continues to constrain its use—especially in medical applications. To strengthen PLA parts and broaden their utility, we carried out an orthogonal experimental study examining the effects of five key process parameters—layer thickness, infill density, shell thickness, printing speed, and nozzle temperature—on tensile and flexural performance. The ranking of parameter importance for tensile strength was: infill density &gt; shell thickness &gt; printing speed &gt; layer thickness &gt; nozzle temperature. For flexural strength, the order was: infill density &gt; layer thickness &gt; shell thickness &gt; printing speed &gt; nozzle temperature. A multi-objective optimization that combined range analysis with a comprehensive scoring method pinpointed the optimal settings as: 0.25&#xa0;mm layer thickness, 1.6&#xa0;mm shell thickness, 100% infill density, 40&#xa0;mm&#xa0;s<sup>−1</sup> printing speed, and a nozzle temperature of 215&#xa0;°C. Using patient-specific CT data, we reconstructed a bilateral cranial-defect model and designed a custom protective cover, which was additively manufactured with the optimized parameters. These results extend the practical reach of PLA and offer a validated process window for fabricating individualized cranial-defect protectors via FDM.</p>

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Optimization of FDM-PLA Process Parameters and Additive Manufacturing of Skull Defect Protective Cover

  • 期刊论文

  • 发表日期：

    2025年8月28日

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  • Jiangang Chen,
  • Jiahao Shi,
  • Siyu Mao,
  • Wei Zhao,
  • Yanlong Peng

摘要

Polylactic acid (PLA) is a biodegradable polymer that serves as the principal feedstock in fused deposition modeling (FDM), yet its intrinsic brittleness continues to constrain its use—especially in medical applications. To strengthen PLA parts and broaden their utility, we carried out an orthogonal experimental study examining the effects of five key process parameters—layer thickness, infill density, shell thickness, printing speed, and nozzle temperature—on tensile and flexural performance. The ranking of parameter importance for tensile strength was: infill density > shell thickness > printing speed > layer thickness > nozzle temperature. For flexural strength, the order was: infill density > layer thickness > shell thickness > printing speed > nozzle temperature. A multi-objective optimization that combined range analysis with a comprehensive scoring method pinpointed the optimal settings as: 0.25 mm layer thickness, 1.6 mm shell thickness, 100% infill density, 40 mm s−1 printing speed, and a nozzle temperature of 215 °C. Using patient-specific CT data, we reconstructed a bilateral cranial-defect model and designed a custom protective cover, which was additively manufactured with the optimized parameters. These results extend the practical reach of PLA and offer a validated process window for fabricating individualized cranial-defect protectors via FDM.