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<p>Fused Deposition Modelling (FDM) is a cost-effective additive manufacturing technique for producing biodegradable polymer components like polylactic acid (PLA). As demand for functional 3D printed parts increases, optimising mechanical properties and surface finish is essential. This study investigates the effects of four key FDM parameters layer thickness, nozzle temperature, printing speed, and raster orientation on surface roughness and flexural strength of PLA prints. Experiments were designed using a Taguchi L9 orthogonal array. Surface roughness was evaluated in both horizontal and vertical orientations using arithmetical mean roughness (Ra), root mean square roughness (Rq), and maximum profile height (Rz), while flexural strength was determined via three-point bending tests. For horizontal roughness, the optimal parameters were 0.1&#xa0;mm layer thickness, 220&#xa0;°C nozzle temperature, 90&#xa0;mm/s printing speed, and 90° raster orientation which lead to ~ 1&#xa0;μm, while for vertical roughness, the best results were obtained with 0.1&#xa0;mm layer thickness, 200&#xa0;°C nozzle temperature, 30&#xa0;mm/s printing speed, and 0° raster orientation which lead to ~ 4&#xa0;μm. The vertical optimal parameters closely aligned with those for maximum flexural strength, which were 0.1&#xa0;mm layer thickness, 210&#xa0;°C nozzle temperature, 30&#xa0;mm/s printing speed, and 0° raster orientation, achieving nearly 100&#xa0;MPa due to enhanced interlayer bonding. Raster orientation was found to be the most influential factor for both surface roughness and flexural performance. Scanning electron microscopy (SEM) revealed differences in interlayer bonding and fracture surface characteristics. These results provide practical guidelines for optimising PLA-based FDM manufacturing, balancing high mechanical performance, low surface roughness, and efficient build time for biomedical and engineering applications.</p>

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Effect of FDM process parameters on flexural strength and surface roughness characteristics of PLA prints

  • 期刊论文

  • 发表日期：

    2026年1月3日

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  • Nejmeddine Layeb,
  • Najoua Barhoumi,
  • Istvan Oldal,
  • László Zsidai

摘要

Fused Deposition Modelling (FDM) is a cost-effective additive manufacturing technique for producing biodegradable polymer components like polylactic acid (PLA). As demand for functional 3D printed parts increases, optimising mechanical properties and surface finish is essential. This study investigates the effects of four key FDM parameters layer thickness, nozzle temperature, printing speed, and raster orientation on surface roughness and flexural strength of PLA prints. Experiments were designed using a Taguchi L9 orthogonal array. Surface roughness was evaluated in both horizontal and vertical orientations using arithmetical mean roughness (Ra), root mean square roughness (Rq), and maximum profile height (Rz), while flexural strength was determined via three-point bending tests. For horizontal roughness, the optimal parameters were 0.1 mm layer thickness, 220 °C nozzle temperature, 90 mm/s printing speed, and 90° raster orientation which lead to ~ 1 μm, while for vertical roughness, the best results were obtained with 0.1 mm layer thickness, 200 °C nozzle temperature, 30 mm/s printing speed, and 0° raster orientation which lead to ~ 4 μm. The vertical optimal parameters closely aligned with those for maximum flexural strength, which were 0.1 mm layer thickness, 210 °C nozzle temperature, 30 mm/s printing speed, and 0° raster orientation, achieving nearly 100 MPa due to enhanced interlayer bonding. Raster orientation was found to be the most influential factor for both surface roughness and flexural performance. Scanning electron microscopy (SEM) revealed differences in interlayer bonding and fracture surface characteristics. These results provide practical guidelines for optimising PLA-based FDM manufacturing, balancing high mechanical performance, low surface roughness, and efficient build time for biomedical and engineering applications.