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<p>Advances in additive manufacturing, particularly multi-nozzle fused deposition modeling (FDM), enable the fabrication of multi-material composites with tailored mechanical properties. In this study, sandwich structures composed of PLA, ABS, and HIPS were systematically evaluated in six layer-ordering configurations under a Taguchi L27 experimental design. Seven process parameters layer thickness, raster angle, build orientation, raster width, print speed, infill density, and material sequence were varied, and flexural performance was quantified using ASTM D6272 four-point bending tests, supported by interfacial microscopy. The results show that the ABS–PLA–ABS configuration achieved the highest flexural strength, with a maximum of 64.96 MPa, whereas PLA-faced laminates such as PAP displayed brittle fracture and lower strain-to-failure. Configurations with ductile outer layers (ABS, HIPS) exhibited greater energy absorption and reduced variability, consistent with microscopy evidence of fewer voids and improved interfacial bonding. By contrast, PLA-faced laminates revealed larger voids and uneven interfaces that acted as crack initiation sites. This work demonstrates that both process optimization and material placement govern ductile-to-brittle transitions in multi-material FDM structures. The findings provide practical guidelines for optimizing printing parameters and material placement to enhance flexural performance.</p>

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Flexural performance and interfacial bonding of PLA/ABS/HIPS composites in multi-nozzle 3D printing

  • 期刊论文

  • 发表日期：

    2025年11月25日

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  • Andri Nasution,
  • Muhammad Luthfi Hakim,
  • Herianto Herianto,
  • Achmad Pratama Rifai

摘要

Advances in additive manufacturing, particularly multi-nozzle fused deposition modeling (FDM), enable the fabrication of multi-material composites with tailored mechanical properties. In this study, sandwich structures composed of PLA, ABS, and HIPS were systematically evaluated in six layer-ordering configurations under a Taguchi L27 experimental design. Seven process parameters layer thickness, raster angle, build orientation, raster width, print speed, infill density, and material sequence were varied, and flexural performance was quantified using ASTM D6272 four-point bending tests, supported by interfacial microscopy. The results show that the ABS–PLA–ABS configuration achieved the highest flexural strength, with a maximum of 64.96 MPa, whereas PLA-faced laminates such as PAP displayed brittle fracture and lower strain-to-failure. Configurations with ductile outer layers (ABS, HIPS) exhibited greater energy absorption and reduced variability, consistent with microscopy evidence of fewer voids and improved interfacial bonding. By contrast, PLA-faced laminates revealed larger voids and uneven interfaces that acted as crack initiation sites. This work demonstrates that both process optimization and material placement govern ductile-to-brittle transitions in multi-material FDM structures. The findings provide practical guidelines for optimizing printing parameters and material placement to enhance flexural performance.