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<p>Carbon fiber reinforced polylactic acid (PLA-CF) has emerged as a promising filament for fused deposition modeling (FDM) owing to its enhanced stiffness, dimensional stability, and suitability for lightweight functional components. Despite this potential, correlating FDM printing parameters with tribological performance remains insufficiently addressed. This study investigates the dry sliding wear behaviour of FDM-fabricated PLA-CF specimens using a full factorial design (3<sup>3</sup>), systematically varying nozzle diameter, extrusion temperature, and layer height across 27 experimental combinations. Wear tests were conducted on a pin-on-disc tribometer at 30&#xa0;N normal load, 500&#xa0;rpm, and 400&#xa0;s sliding duration. Wear loss ranged from 840 to 1980&#xa0;µm, friction forces between 2.1 and 5.5&#xa0;N, and coefficients of friction from 0.07 to 0.18. Analysis of variance identified layer height as the dominant parameter, with nozzle diameter and extrusion temperature contributing primarily through interaction effects. A significant three-way interaction governed the overall tribological response, highlighting the inadequacy of single-factor optimization approaches. X-ray diffraction confirmed the semi-crystalline PLA matrix with graphitic carbon reinforcement. Scanning electron microscopy of worn surfaces revealed abrasive grooves, debris accumulation, and localized matrix deformation, confirming combined abrasive and adhesive wear mechanisms. These findings establish a process structure property framework for targeted FDM parameter optimization in tribological service conditions.</p>

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Influence of Nozzle Diameter, Extrusion Temperature, and Layer Height on the Tribological Performance of FDM-Printed PLA-Carbon Fiber Composites

  • 期刊论文

  • 发表日期：

    2026年5月28日

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  • R. Karthikeyan,
  • V. P. Pradeep,
  • V. S. Sreebalaji

摘要

Carbon fiber reinforced polylactic acid (PLA-CF) has emerged as a promising filament for fused deposition modeling (FDM) owing to its enhanced stiffness, dimensional stability, and suitability for lightweight functional components. Despite this potential, correlating FDM printing parameters with tribological performance remains insufficiently addressed. This study investigates the dry sliding wear behaviour of FDM-fabricated PLA-CF specimens using a full factorial design (33), systematically varying nozzle diameter, extrusion temperature, and layer height across 27 experimental combinations. Wear tests were conducted on a pin-on-disc tribometer at 30 N normal load, 500 rpm, and 400 s sliding duration. Wear loss ranged from 840 to 1980 µm, friction forces between 2.1 and 5.5 N, and coefficients of friction from 0.07 to 0.18. Analysis of variance identified layer height as the dominant parameter, with nozzle diameter and extrusion temperature contributing primarily through interaction effects. A significant three-way interaction governed the overall tribological response, highlighting the inadequacy of single-factor optimization approaches. X-ray diffraction confirmed the semi-crystalline PLA matrix with graphitic carbon reinforcement. Scanning electron microscopy of worn surfaces revealed abrasive grooves, debris accumulation, and localized matrix deformation, confirming combined abrasive and adhesive wear mechanisms. These findings establish a process structure property framework for targeted FDM parameter optimization in tribological service conditions.