The influence of fused filament fabrication parameters on the fracture behavior of pla specimens considering energy consumption

Abstract

Fused Filament Fabrication (FFF) is a 3D (three-dimensional) printing technology that allows the production of polymers with a wide range of infill densities and unlimited geometric variations. Because of this flexibility, mechanical properties can be optimized by tuning printing parameters. However, the energy consumption during fabrication varies significantly for different printing settings. In the present study, both maximum fracture force and minimum energy consumption of 3D printed PLA (Polylactic Acid) are achieved together by optimizing the printing parameters using CPA (Cyclical Parthenogenesis Algorithm) optimization algorithm. Firstly, a quasi-static penetration test is performed to measure the maximum fracture force. The energy consumption of each specimen is also calculated. Then, maximum fracture force and energy consumption are modeled and integrated into the optimization algorithm. As a result, the three most convenient parameter levels are 84%, 6.83 mm, and 0.19 mm for infill ratio, specimen thickness, and layer height, respectively. While high infill ratio values and specimen thickness increase mechanical performance, these parameter levels are disadvantageous for energy consumption. As a result of optimization, parameters that provide balanced strength and energy consumption were obtained. Fracture force and energy consumption are 1829.87 N and 134.56 W, respectively for the validation experiment of the optimal solution.