Impact of processing parameters on tensile strength, in-process crystallinity and mesostructure in FDM-fabricated PLA specimens

This study aims to investigate the impact of layer thickness, extrusion temperature, extrusion speed and build plate temperature on the tensile strength, crystallinity achieved during fabrication (herein, in-process crystallinity) and mesostructure of Poly(lactic acid) specimens. Both tensile strength and in-process crystallinity were optimized and verified as the function of processing parameters, and their relationship was thoroughly examined.

The four key technological parameters were systematically varied as factors on three levels, using the statistically designed experiment. Surface response methodology was used to optimize tensile strength and crystallinity for the given ranges of input factors. Optimized factor settings were used in a set of confirmation runs, where the result of optimization was experimentally confirmed. Material characterization was performed using differential scanning calorimetry and X-ray diffraction analysis, while the effect of processing parameters on mesostructure was examined by scanning electron microscopy.

Layer thickness and its quadratic effect are dominant contributors to tensile strength. Significant interaction between layer thickness and extrusion speed implies that these parameters should always be varied simultaneously within designed experiment to obtain adequate process model. As regards, the in-process crystallinity, extrusion speed is part of two significant interactions with plate temperature and layer thickness, respectively. Quality of mesostructure is vital contributor to tensile strength during FDM process, while the in-process crystallinity exhibited no impact, remaining below the 20 per cent margin regardless of process parameter settings.

According to available literature, there have been no previously published investigations which studied the effect of process parameters on tensile strength, mesostructure and in-process crystallinity through systematic variation of four critical processing parameters.