Experimental optimization of process parameters on mechanical properties and the layers adhesion of 3D printed parts

Additive manufacturing by fused filament fabrication provides an innovative manufacturing process for new design vision and complex geometry components. This study aims to establish the relationships between the process parameters and the mechanical properties of 3D printed parts using Taguchi design of experiment. The proposed method also enables the study of the filling orientation effects on the cohesion of the printed layers and the overall fracture behavior. We reviewed and optimized the effects of the critical parameters of process such as the layer thickness, the temperature, the print speed, and the filling orientation on Young's modulus and tensile strength. Then the effect of raster angle on the cohesion between the printed layers, as well as the failure modes were analyzed. The results show that the layer thickness and the filling angle are more influential on the mechanical properties. An analysis of the fracture surfaces of tensile specimens was also performed and it indicated a fracture following the filling direction. Furthermore, the fill angle 0/90 degrees shows the best adhesion between the printed layers.