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<p>The present study investigates the mechanical behavior of 3D-printed adhesive-bonded single-lap joints (SLJs) under varying thermal loading conditions using a statistical optimization framework. Although adhesive bonding is widely used for lightweight structures, limited attention has been given to the combined effects of surface pattern geometry, material pairing, and temperature on joint performance in additively manufactured components. In this work, joints incorporating four distinct surface patterns (flat, 0°, 45°, and 90°) and four material pairings (PLA/PLA, PLA/ABS, ABS/ABS, and ABS/PLA) were fabricated using the fused deposition modeling (FDM) technique. The Taguchi L16 orthogonal array design was employed to efficiently analyze the influence of these parameters on lap shear strength across four thermal conditions (30, 40, 50, and 60&#xa0;°C). Experimental and statistical results revealed that temperature was the most dominant factor, contributing 80.68% of the variance, followed by surface pattern (13.50%) and material pairing (2.43%). The optimal combination 45° surface pattern, 30&#xa0;°C temperature, and ABS/ABS pairing yielded the highest joint strength. The findings demonstrate the strong coupling between thermal exposure and geometrical interlocking in determining joint integrity and establish a reliable Taguchi-based framework for optimizing adhesive-bonded 3D-printed structures operating under thermal environments.</p>

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Study on the Mechanical Behavior of 3D-Printed Adhesive-Bonded Joints under Different Thermal Loading Using the Taguchi (L16) Method

  • 期刊论文

  • 发表日期：

    2026年1月22日

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  • P. Pragathi,
  • S. Jeba Jenison,
  • R. Velmurugan

摘要

The present study investigates the mechanical behavior of 3D-printed adhesive-bonded single-lap joints (SLJs) under varying thermal loading conditions using a statistical optimization framework. Although adhesive bonding is widely used for lightweight structures, limited attention has been given to the combined effects of surface pattern geometry, material pairing, and temperature on joint performance in additively manufactured components. In this work, joints incorporating four distinct surface patterns (flat, 0°, 45°, and 90°) and four material pairings (PLA/PLA, PLA/ABS, ABS/ABS, and ABS/PLA) were fabricated using the fused deposition modeling (FDM) technique. The Taguchi L16 orthogonal array design was employed to efficiently analyze the influence of these parameters on lap shear strength across four thermal conditions (30, 40, 50, and 60 °C). Experimental and statistical results revealed that temperature was the most dominant factor, contributing 80.68% of the variance, followed by surface pattern (13.50%) and material pairing (2.43%). The optimal combination 45° surface pattern, 30 °C temperature, and ABS/ABS pairing yielded the highest joint strength. The findings demonstrate the strong coupling between thermal exposure and geometrical interlocking in determining joint integrity and establish a reliable Taguchi-based framework for optimizing adhesive-bonded 3D-printed structures operating under thermal environments.