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<p>Porosity is a significant challenge in the material extrusion (MEX) process for prototype fabrication, as it directly impacts the strength of MEX-based components. While various process parameters affecting porosity have been extensively studied, the role of line width (LW) has often been overlooked. This study investigates the influence of layer height (LH), LW, and infill pattern (IP) on the mechanical properties, specifically ultimate tensile strength (UTS), flexural strength (FS), and the size and shape of porosity. The samples were constructed using four levels of LH (0.1, 0.2, 0.3, and 0.4&#xa0;mm) and LW (0.1, 0.2, 0.3, and 0.4&#xa0;mm), combined with four different infill patterns (triangle, tri-hexagon, line, and gyroid). Taguchi and ANOVA analyses were employed to determine the effects of these parameters. The results indicated that samples with LH = 0.4&#xa0;mm, LW = 0.4&#xa0;mm, and a tri-hexagon infill pattern exhibited the highest UTS of 54.18&#xa0;MPa. Additionally, the sample with LH = 0.3&#xa0;mm, LW = 0.4&#xa0;mm, and a tri-hexagon pattern showed the maximum flexural strength of 81.01&#xa0;MPa. SEM analysis was conducted to study the fracture surface morphology. Furthermore, infill line density calculations revealed that line, concentric, and zigzag patterns printed with no gap between the beads, whilst predefined geometry patterns like triangles and gyroids created distinct voids. These findings emphasise the importance of the LW and infill pattern in optimising the mechanical properties and porosity of MEX-based components.</p>

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Design and investigation of the influence of process parameters on material-extruded (MEX) PLA: porosity shape and size, tensile and flexural strength

  • 期刊论文

  • 发表日期：

    2025年5月27日

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  • Dharavathu Naresh,
  • Pramod Kotnala

摘要

Porosity is a significant challenge in the material extrusion (MEX) process for prototype fabrication, as it directly impacts the strength of MEX-based components. While various process parameters affecting porosity have been extensively studied, the role of line width (LW) has often been overlooked. This study investigates the influence of layer height (LH), LW, and infill pattern (IP) on the mechanical properties, specifically ultimate tensile strength (UTS), flexural strength (FS), and the size and shape of porosity. The samples were constructed using four levels of LH (0.1, 0.2, 0.3, and 0.4 mm) and LW (0.1, 0.2, 0.3, and 0.4 mm), combined with four different infill patterns (triangle, tri-hexagon, line, and gyroid). Taguchi and ANOVA analyses were employed to determine the effects of these parameters. The results indicated that samples with LH = 0.4 mm, LW = 0.4 mm, and a tri-hexagon infill pattern exhibited the highest UTS of 54.18 MPa. Additionally, the sample with LH = 0.3 mm, LW = 0.4 mm, and a tri-hexagon pattern showed the maximum flexural strength of 81.01 MPa. SEM analysis was conducted to study the fracture surface morphology. Furthermore, infill line density calculations revealed that line, concentric, and zigzag patterns printed with no gap between the beads, whilst predefined geometry patterns like triangles and gyroids created distinct voids. These findings emphasise the importance of the LW and infill pattern in optimising the mechanical properties and porosity of MEX-based components.