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<p>The Fused Deposition Modeling (FDM) additive manufacturing process significantly influences the water absorption behavior of printed parts, affecting their mechanical performance and long-term durability. This study examines the water absorption and surface stability of FDM 3D-printed PETG disks immersed in distilled water at 25&#xa0;°C for 84&#xa0;days, focusing on the role of layer thickness (0.1, 0.2, 0.3&#xa0;mm) and wall count (2, 4, 6). The absorption process followed a Fickian diffusion model, characterized by an induction phase with negligible weight change for the first 14&#xa0;days, followed by rapid absorption and eventual equilibrium by day 84. Results show that final mass gain increased with both wall count and layer thickness, a trend governed by the interplay between inter-layer porosity and the total volume of hygroscopic material. For instance, reducing the layer thickness from 0.3&#xa0;mm to 0.1&#xa0;mm (at 6 walls) decreased water uptake by a remarkable 57%, while increasing the wall count from 2 to 6 (at 0.3&#xa0;mm layer thickness) increased absorption by 42%. Nozzle temperature in the range of 230-250&#xa0;°C had no significant effect. Morphological analysis after 84&#xa0;days revealed that samples with thicker layers and more walls preserved their surface integrity, whereas those with thinner layers and fewer walls exhibited severe distortion, surface pits (up to 900&#xa0;µm radius), and delamination. This work demonstrates for the first time that by optimizing FDM parameters—specifically, reducing layer thickness—water uptake can be more than halved, significantly enhancing the durability and surface quality of PETG parts for humid or submerged applications. Ultimately, both wall count and layer thickness must be carefully balanced to achieve minimal moisture absorption and maximum structural stability in demanding environments.</p>

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Effect of Layer Thickness and Wall Count on Moisture Diffusion in FDM-Printed PETG Structures

  • 期刊论文

  • 发表日期：

    2025年11月10日

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  • Amir Mohsen Borhanianghanad,
  • Mahdi Kazemi,
  • Babak Houshmand

摘要

The Fused Deposition Modeling (FDM) additive manufacturing process significantly influences the water absorption behavior of printed parts, affecting their mechanical performance and long-term durability. This study examines the water absorption and surface stability of FDM 3D-printed PETG disks immersed in distilled water at 25 °C for 84 days, focusing on the role of layer thickness (0.1, 0.2, 0.3 mm) and wall count (2, 4, 6). The absorption process followed a Fickian diffusion model, characterized by an induction phase with negligible weight change for the first 14 days, followed by rapid absorption and eventual equilibrium by day 84. Results show that final mass gain increased with both wall count and layer thickness, a trend governed by the interplay between inter-layer porosity and the total volume of hygroscopic material. For instance, reducing the layer thickness from 0.3 mm to 0.1 mm (at 6 walls) decreased water uptake by a remarkable 57%, while increasing the wall count from 2 to 6 (at 0.3 mm layer thickness) increased absorption by 42%. Nozzle temperature in the range of 230-250 °C had no significant effect. Morphological analysis after 84 days revealed that samples with thicker layers and more walls preserved their surface integrity, whereas those with thinner layers and fewer walls exhibited severe distortion, surface pits (up to 900 µm radius), and delamination. This work demonstrates for the first time that by optimizing FDM parameters—specifically, reducing layer thickness—water uptake can be more than halved, significantly enhancing the durability and surface quality of PETG parts for humid or submerged applications. Ultimately, both wall count and layer thickness must be carefully balanced to achieve minimal moisture absorption and maximum structural stability in demanding environments.