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<p>Material extrusion (MEX) is a widely used additive manufacturing technique because of its ability to fabricate complex geometries through layer-by-layer deposition. However, traditional uniform-layer-height printing often results in interlayer voids during the preprocessing stage, which act as stress concentrators and degrade mechanical and fatigue performance. This study introduces a novel Alternating Layer Height (ALH) printing strategy aimed at minimizing interlayer porosity and enhancing interfacial bonding. A Box–Behnken design was employed to systematically optimize key process parameters, with statistical validation conducted using a regression model analysis. Experimental results revealed that the ALH strategy led to a 33% reduction in interlayer porosity compared to traditional uniform-layer printing, without compromising intra-layer quality. This improvement resulted in a 14.14% increase in flexural strength and a 40.42% enhancement in impact resistance. Most notably, the fatigue life of PLA specimens increased by 68.7%, demonstrating the ability of the ALH strategy to delay crack initiation and early propagation through improved interfacial integrity. Additionally, the strategy achieved a 30.57% reduction in printing time, thereby improving process throughput. Dimensional accuracy in the Z-direction was enhanced with a deviation limited to 2.9%. However, surface roughness increased by 43.84%, indicating a trade-off in surface finish due to the variable layer heights. The proposed ALH method offers a practical solution for improving mechanical performance, manufacturing efficiency, and fatigue life in MEX-based systems. These findings are particularly relevant for industries seeking to optimize additive manufacturing workflows for structural applications while reducing processing time and energy consumption.</p>

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A novel technique to reduce the interlayer voids through alternative layer thickness at preprocessing stage of MEX process: to enhance fatigue life of PLA build parts

  • 期刊论文

  • 发表日期：

    2025年9月29日

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  • Naresh Dharavathu,
  • D Narsimhachary,
  • B Dharmabiksham

摘要

Material extrusion (MEX) is a widely used additive manufacturing technique because of its ability to fabricate complex geometries through layer-by-layer deposition. However, traditional uniform-layer-height printing often results in interlayer voids during the preprocessing stage, which act as stress concentrators and degrade mechanical and fatigue performance. This study introduces a novel Alternating Layer Height (ALH) printing strategy aimed at minimizing interlayer porosity and enhancing interfacial bonding. A Box–Behnken design was employed to systematically optimize key process parameters, with statistical validation conducted using a regression model analysis. Experimental results revealed that the ALH strategy led to a 33% reduction in interlayer porosity compared to traditional uniform-layer printing, without compromising intra-layer quality. This improvement resulted in a 14.14% increase in flexural strength and a 40.42% enhancement in impact resistance. Most notably, the fatigue life of PLA specimens increased by 68.7%, demonstrating the ability of the ALH strategy to delay crack initiation and early propagation through improved interfacial integrity. Additionally, the strategy achieved a 30.57% reduction in printing time, thereby improving process throughput. Dimensional accuracy in the Z-direction was enhanced with a deviation limited to 2.9%. However, surface roughness increased by 43.84%, indicating a trade-off in surface finish due to the variable layer heights. The proposed ALH method offers a practical solution for improving mechanical performance, manufacturing efficiency, and fatigue life in MEX-based systems. These findings are particularly relevant for industries seeking to optimize additive manufacturing workflows for structural applications while reducing processing time and energy consumption.