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<p>Fused deposition modeling (FDM) is a widely used additive manufacturing technique for fabricating complex geometries from thermoplastic polymers, specifically polylactic acid (PLA) and thermoplastic polyurethane (TPU). Understanding the influence of material behavior and infill design on structure–property relationships is limited and needs further investigation. This study examines the structure–property relationships of FDM 3D-printed PLA and TPU under identical processing conditions using three infill patterns (zig-zag, tri-hexagon, and octet) and five infill densities (20%, 40%, 60%, 80%, and 100%), followed by mechanical, thermal, and morphological characterizations. PLA exhibited high stiffness and mechanical strength, with maximum tensile, flexural, and compressive strengths of ~ 49&#xa0;MPa, ~ 72&#xa0;MPa, and ~ 67&#xa0;MPa, respectively, obtained across different infill patterns, but showed brittle fracture due to interlayer debonding. In contrast, TPU exhibited lower strengths (~41&#xa0;MPa tensile, ~ 3&#xa0;MPa flexural, and ~ 30&#xa0;MPa compressive) with performance varying across infill patterns, but demonstrated significant ductility, energy absorption, and reversible deformation. Thermal analysis indicated a single-step degradation process and relatively sharp transitions for PLA, whereas TPU exhibited multiple relaxation processes and a two-step degradation profile. The results demonstrate that mechanical performance depends on the combined effect of material behavior, infill geometry, and relative density, providing a basis for the design of FDM-printed structures for applications in soft robotics, biomedical scaffolds, and adaptive systems.</p>

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Mechanical, Thermal, and Morphological Evaluations of Fused Deposition Modeling-Printed Polylactic Acid and Thermoplastic Polyurethane with Varied Infill Designs and Densities

  • 期刊论文

  • 发表日期：

    2026年5月15日

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  • Sibani Mahapatra,
  • Gugulothu Sravanthi,
  • Shampa Aich

摘要

Fused deposition modeling (FDM) is a widely used additive manufacturing technique for fabricating complex geometries from thermoplastic polymers, specifically polylactic acid (PLA) and thermoplastic polyurethane (TPU). Understanding the influence of material behavior and infill design on structure–property relationships is limited and needs further investigation. This study examines the structure–property relationships of FDM 3D-printed PLA and TPU under identical processing conditions using three infill patterns (zig-zag, tri-hexagon, and octet) and five infill densities (20%, 40%, 60%, 80%, and 100%), followed by mechanical, thermal, and morphological characterizations. PLA exhibited high stiffness and mechanical strength, with maximum tensile, flexural, and compressive strengths of ~ 49 MPa, ~ 72 MPa, and ~ 67 MPa, respectively, obtained across different infill patterns, but showed brittle fracture due to interlayer debonding. In contrast, TPU exhibited lower strengths (~41 MPa tensile, ~ 3 MPa flexural, and ~ 30 MPa compressive) with performance varying across infill patterns, but demonstrated significant ductility, energy absorption, and reversible deformation. Thermal analysis indicated a single-step degradation process and relatively sharp transitions for PLA, whereas TPU exhibited multiple relaxation processes and a two-step degradation profile. The results demonstrate that mechanical performance depends on the combined effect of material behavior, infill geometry, and relative density, providing a basis for the design of FDM-printed structures for applications in soft robotics, biomedical scaffolds, and adaptive systems.