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<p>Fused deposition modeling (FDM) is a revolutionary concept for orthopedic immobilization; however, production parameters have yet to be optimized for clinical load bearing. This study demonstrates a link between raster angle and the mechanical performance of polylactic acid plus (PLA + ) bone support devices. Tensile (ASTM D638) and fracture toughness (single-edge notched bend SENB, ASTM D5045) tests were conducted on configurations (0°/90°, ± 45°, 20°/70°, and quasi-isotropic) were investigated using tensile testing (ASTM D638) and fracture toughness evaluation (SENB, ASTM D5045). The ± 45° configuration was identified as the best, with a 30.1% higher fracture toughness (364.2&#xa0;MPa·√m) and 15.7% higher tensile strength than the conventional 0°/90° geometry. The new configuration, proven by finite element analysis with an error within 4.2%, delivers a safety factor of 1.9 under static load. This study demonstrates a validated path to replacing bulky and non-ventilating plaster casts with lightweight, patient-specific PLA + casts, without compromising mechanical safety.</p>

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Raster Angle Optimization of Fused Deposition Modeled Polylactic Acid (PLA)-Based Bone Support Devices: For Enhanced Mechanical Performance in Orthopedic Application

  • 期刊论文

  • 发表日期：

    2026年5月19日

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  • Ahmed Ali Farhan Ogaili,
  • Fadhel Abbas Abdulla,
  • Firas Thair Al-Maliky,
  • Alaa Abdulhady Jaber,
  • Emad Kadum Njim,
  • Mohsin Noori Hamzah,
  • Luttfi A. Al-Haddad,
  • Mustafa I. Al-Karkhi

摘要

Fused deposition modeling (FDM) is a revolutionary concept for orthopedic immobilization; however, production parameters have yet to be optimized for clinical load bearing. This study demonstrates a link between raster angle and the mechanical performance of polylactic acid plus (PLA + ) bone support devices. Tensile (ASTM D638) and fracture toughness (single-edge notched bend SENB, ASTM D5045) tests were conducted on configurations (0°/90°, ± 45°, 20°/70°, and quasi-isotropic) were investigated using tensile testing (ASTM D638) and fracture toughness evaluation (SENB, ASTM D5045). The ± 45° configuration was identified as the best, with a 30.1% higher fracture toughness (364.2 MPa·√m) and 15.7% higher tensile strength than the conventional 0°/90° geometry. The new configuration, proven by finite element analysis with an error within 4.2%, delivers a safety factor of 1.9 under static load. This study demonstrates a validated path to replacing bulky and non-ventilating plaster casts with lightweight, patient-specific PLA + casts, without compromising mechanical safety.