Optimizing tribological performance of 3D-printed poly(lactic acid) components through process parameter analysis

3D printing, a transformative technology in manufacturing, creates objects layer by layer from digital designs, offering customization and cost-effectiveness across industries. This research endeavours to enhance the tribological performance of 3D-printed poly(lactic acid) (PLA) specimens by systematically investigating key process parameters, including infill pattern, layer thickness, orientation, and infill density. The specimens were produced utilizing a QIDI 3D Printer, and their tribological properties were evaluated through linear sliding wear tests performed on a Bio-Tribometer, conforming to the ASTM F732 standard. To efficiently optimize the process, a Taguchi L9 orthogonal array (OA) experimental design plan was chosen for its inherent efficiency, robustness, and cost-effectiveness. Utilizing the results of the ANOVA (Analysis of Variance) conformation tests, the optimal process parameters were identified, and thus the tribological performance of the 3D-printed PLA specimens was improved. Analysis revealed that the orientation of the printed objects exerts the most substantial influence on tribological performance, followed by layer thickness, infill pattern and infill density. The confirmation tests substantiate that these optimal process parameters yield a remarkable 64.912% reduction in wear, a 16.667% decrease in the coefficient of friction (CoF), and a notable 6.3% increase in hardness. Furthermore, regression models were developed to analyze and predict wear, CoF and hardness, contributing to a profound understanding of the interplay between process parameters and material performance. The insights derived from this study pave the way for predicting and implementing optimal tribological conditions in the production of 3D-printed products, with significant implications for material wear reduction and enhanced product durability.