Journal of Engg.

Research, ICMMM Special Issue

Effect of Printing Parameters of 3D Printed PLA Parts

on Mechanical Properties

DOI:10.36909/jer.ICMMM.15697

Jayakumar N*, Senthilkumar G, Pradeep A D

Department of Mechanical Engineering, Assistant Professor, Bannari Amman Institute of

Technology, Sathyamangalam, Tamilnadu, 638401, India

*Corresponding Author: [email protected]

ABSTRACT

Additive manufacturing significantly reduces the lead time of the product development cycle

in the way of design trials and thus reduces delivery time to the market. The essence has been

understood by many sectors including, education, manufacturing industries, automotive,

medical, aerospace, consumer electronics, bio-medical and even fashion enthusiasts. It is used

to prepare this PLA for the used plastics and landfills. By this way, it can reduce the plastics

waste from the earth. Compare with ABS plastics, PLA plastics are cheaper. This disruptive

technology going to the change the way of manufacturing goods and sets a new narrow path

to the future industries. During usage of filament material, it’s got failure due to not enough

quality printing because of not proper process parameters. Also, the printed part does not have

good surface quality. So, the PLA material requires improved mechanical properties. The

objective of this study is to create 3D printed parts with good quality with the optimized

process parameters.The selected process parameters are infill density (%), Nozzle temperature

(º) and print orientation. Taguchi orthogonal array (L9) design method has been chosen for

generating design of experiments. The samples are produced according to its ASTM

standards. The specimens were tested for identifying the mechanical properties like tensile

strength, compression strength and impact strength. From the results obtained from the tests,

taking the mean values and conclude the better infill density, orientation and the nozzle

temperature the PLA.

Keywords: FDM; PLA; Taguchi; ASTM.

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Journal of Engg. Research, ICMMM Special Issue

INTRODUCTION
Polylactic Acid (PLA) is not a usual kind of thermoplastic polymers in this, it is prepared

from the sustainable assets such as corn starch and sugar stick. Most of the plastics are getting

from the refining process and polymerization process of non-renewable oil holdings. The PLA

which are getting from biomass (for example PLA) are called as "bioplastics". Polylactic Acid

are biodegradable and have the attributes like polystyrene (PS), polypropylene (PP) and

polyethylene (PE). It tends to be created from previously existed assembling gears (this

planned and initially utilized for the Petro-chemical industry plastics). It makes moderately

cost efficient to create. As requires be, PLA have the second largest creating quantity of any

bio degradable plastic (a most well-known ordinarily referred to as thermo-plastic starch).

They are an immense range of utilizations for the Polylactic Acid. The exact uses are in

incorporate plastic bottles and bio-degradable clinical components (for example pins, screws,

poles, and plastic plates that are required to bio-degrade in 6 years). In addition, on clinical

gadget models (both are bio-degradable and are perpetual). PLA contracts are under heating

and are in this way appropriate for used as the psychologist wraps material. Furthermore, the

similarity with Polylactic Acid melt taking into consideration for some modern applications

with regards to 3D printing.

The advancement of combined testimony displaying boundaries for improved PLA and ABS

3D printed structures. The properties of 3D printed examples (i.e., mechanical, warm and

morphological) with fluctuating preparing conditions, for example, infill design, infill

thickness and infill speed, and furthermore with various printing materials. Various testing

methods, for example, pliable, twisting, pressure, differential filtering calorimetry (DSC),

warm gravimetric investigation (TGA), warm imaging, and examining electron microscopy

(SEM) were utilized for playing out a far-reaching examination. By and large, 100% infill

thickness, 90 mm/s infill speed, 215ºC of set spout temperature, and the direct fill design were

the conceivable ideal interaction settings for the most improved exhibition of the five

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distinctive printing materials (Abeykoon, P. Sri-Amphorn, and A. Fernando et al., 2020).

Optimization of Fused Deposition Modeling Processing Parameters and Design for

Manufacturing approach. To examine the free impact of each preparing boundary on the

mechanical properties and dimensional precision repeatability of FDM parts. An aggregate of

18 test example tests were printed utilizing fluctuating handling boundaries. Examine the

repeatability and came about resilience, the components of these examples were estimated and

contrasted and a 3D CAD model. It was shown that the mechanical properties are affected

fundamentally constructing heading, expulsion temperature, and layer stature; and to a lesser

extent on infill designs, for high infill rates examples, and printing speed. (Alafaghani, A.

Qattawi, B. Alrawi, and A. Guzman et al.,2017)

Using FDM technique the impact of process parameters on the tensile properties of prepared

specimen was studied. ULTEM 9085 is used with full factorial design of experiment. There

are five parameters considered for examination like air gap, raster width, raster angle, contour

number and contour width. It is noted that only one parameter (raster angle) significantly

influenced the tensile properties of the material among the considered parameters. (W. Gebisa

and H. G. Lemu et al., 2019)

To accomplish 3D printing of PEEK the FDM technique is used. To reproduce the dissolving

conditions and fluidity of PEEK in a flow channel, the Finite Element Analysis (FEA) was

used. The reenactments results were additionally investigated to instruct the arrangement of

future printing structure and upgrade the printing limits. Moreover, a few FDM tests were

performed to consider the impacts of various printing limits, including the printing

temperature, printing speed, and printing layer thickness, on the mechanical properties,

microstructure, and surface nature of printed PEEK parts. The results suggested that using a

higher warming temperature of 440 °C, a printing rate of 20 mm/s, and a little printing layer

thickness of 0.1 mm can improve the thickness of PEEK parts, diminish inner imperfections,

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Journal of Engg. Research, ICMMM Special Issue

fortify restricting between 3D printed layers and infill filaments, and lessen surface

unpleasantness. (P. Wang, B. Zou, H. Xiao, S. Ding, and C. Huang et al., 2019)

In the writing there are numerous works concerning the mechanical portrayal of the PLA at

the same time, because of the regular orthotropy of the FDM interaction and, most

importantly, to the discovered impact of the specific specialized framework with which the

activities are performed, it is important to describe the expelled material through various

metrological procedures. 6 examples for every course (level, on side, vertical, figure 2) have

been printed for a sum of 18 examples for the static elastic test. Through this subjective

examination of the area of the crack point, an alternate conduct between vertical examples and

the other two sets (on side and even) is apparent. (D. Corapi, G. Morettini, G. Pascoletti, and

C. Zitelli et al., 2019)

POLYLACTIC ACID

Polylactic Acid are essentially made from two distinct cycles: they are building up and

polymerization. They are most widely recognized in polymerization method is called as ring-

opening polymerization. It is an interaction that use the metal impet use in mix with the

lactide to make the biggest PLA atoms. The building up interaction is comparative with

important contrast being in the temperature during the strategy and the result are delivered as

an outcome of that response. Since we understand that what it is to be utilized for, we

analyze a portion of a critical property of Polylactic Acid. PLA is called as "thermoplastic"

polyester. Thermoplastic materials become fluid at the time of dissolving point (150-1600C

on account of PLA). A significant valuable property of the thermoplastics is that this can be

warm to their liquefying point, and then cooled, and warm again without huge debasement.

Rather than consuming, thermoplastics like Polylactic Acid condense, which permits them to

be effectively infusion formed and afterward in this way reused. Paradoxically, thermoset

plastics must be warmed once (normally during the infusion shaping cycle). PLA is its

biodegradable nature and the maintainable interaction by which it is made, settling on it the

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harmless to the ecosystem decision of plastic. Table 1. Shows the properties of polylactic

acid.Properties of polylactic acid: Diameter: 1.75mm +/- 0.02 mm, Printing Temperature:

190-210°C and Bed Temperature:60°C

Table 1. Properties of Polylactic acid

Property Value Units Testmethod

Generalproperties
Specificgravity 1.24 g/cm3 ASTMD792
Mechanicalproperties
Flexuralelasticmodules 3600 MPa ISO178
Flexuralstrength 108 MPa ISO178
Hardness.ShD 85 Sh D ASTMD2240
Thermalproperties
Heat distortion 56 °C ISO75/2B

temperatureHDT B(0.45MPa)

Meltingtemperature 145-160 °C ASTMD3418

Gas distortion 56-64 °C ASTMD3418

SPECIMEN DESIGN
temperature
ASTM D638 Type 1 for the tensile test of the PLA polymers as shown in Figure 1. ASTM

standards of ASTM D256 – 10 for the impact test as shown in Figure 2. and ASTM D695 for

the compression test.

Figure 1. Tensile test specimen-ASTM Figure 2. Impact test specimen-ASTM

After the selection of the parameters the test, the samples are segregated and differentiated by

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Journal of Engg. Research, ICMMM Special Issue

using Taguchi method. The specimens are to be designed first as CAD file and then are to be

converted to 3D printing format. The specimens are prepared based on the types of

mechanical tests to be taken. As this is a polymer composite, their ASTM standards design

can be in consideration while drafting the design. The design for specimen is done using

SOLIDWORKS software and set with tolerance limit in consideration with thermal expansion

while 3D printing process. Figures 3, 4 & 5 shows the design of tensile test, impact test and

compression test specimen.

Figure 3. Tensile test specimen Figure 4. Impact test specimen

Figure 5. Compression test specimen Figure 6. PLA Filament spool

FABRICATION OF SPECIMEN

The fabrication of specimen is done by using 3D printing technique. Creality 3D ender printer

has used for this process due to its high accuracy in printing and reliability. PLA material of

high quality and white color (filament type) weighing 1 kg is used in the fabrication process.

Figure 6. illustrates the PLA material used in the process. Creality machine is cleaned

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thoroughly before the printing process to ensure proper printing and the nozzle has air blown

to remove particles present in it.

3D printer fiber spools come in a wide range of styles and sizes. Most 3D printers will

acknowledge spools that fall inside a bunch of industry acknowledged guidelines. Our spools

are intended to fit most 3D printers that acknowledge a standard spool size.

Bigger fiber spools take into account consistent 3D printing without changing out the spool

and intrude on prints. A greater spool is ideal for a bigger form that necessary more 3D printer

fiber. This may even be ideal for more modest prints on the off chance that you are burnt out

on changing out spools so frequently.

DESIGN OF EXPERIMENTS

In this paper, the Taguchi Method is used for the better selection of the specimens as shown in

Table 2. The L9 array is used because of the three parameters such as infill density, print

orientation and nozzle temperature. Each test is having 9 specimens. So, a total of 27

specimens has to be prepared. In this, nozzle temperature changes are done at the 3D printing

machine only.

Table 2. Taguchi L9 table

Trial A B C
1 1 1 1
2 1 2 2
3 1 3 3
4 2 1 2
5 2 2 3
6 2 3 1
7 3 1 3
8 3 2 1
9 3 3 2

EXPERIMENTAL PROCEDURE
After the fabrication and post treatment of prepared specimen they are subjected to various

Mechanical tests such Tensile test, Impact test, compression test to better understand the

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Mechanical behaviour of the prepared specimen. The tests are done as per the ASTM

standards and with utmost care to undermine the best results possible. The results are noted

down from each test taken and graphs are plotted based on it. The graphs would give us a

glimpse of how the different specimen behaved for different tests taken and find out the better

combination for making a better product. Further on the note results and conclusion can be

drawn out.

TENSILE TEST

Tensile test is taken out for the specimen to study their breaking nature and elongation

properties. FIE Universal Tensile tester (Figure 7.) was used in the process of testing. The

specimens were fixed between the top and bottom jaws of the machine. As the test process

starts, the upper jaw moves upward while the lower jaw remains constant. At certain point the

specimen breaks, indicating its max breaking capacity. The results are all obtained in the

software and graphs are also generated for the same and the results can be customized based

on the requirement with graph plotting too. Figure 8. shows the different tensile test specimen

before the test is taken.

Figure 7. FIE Tensile Testing Machine Figure 8. Tensile test specimen before testing

IMPACT TEST

Impact test of specimen are taken out to study the energy absorbing capacity of the polymer

composite. The test taken here is Izod Impact test for the specimen. The specimen is placed in

the bottom area of the stand between the verticals. The striker of certain load capacity is taken

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and placed at certain height for release.

Figure 9. Impact Testing Machine Figure 10. Impact test specimen before testing

The striker is released down for testing and it hits hard at the specimen, thus breaking it into

two separate pieces. Figure 9. shows an Impact testing machine in operation. The impact

energy value is shown by the dial as soon as the striker hits the specimen. The value is

measured in Joules and it noted down for further study. Figure 10. shows the typical

specimens used for the Impact test. These are mechanically operated machines and the values

obtained are also in a mechanical dial, thus accuracy of measurement may slightly differ from

digitized one.

COMPRESSION TEST

Compression testis done in the compression testing machine. The specimens are cube like

structure as shown in Figure 11. The sample is placed in between the two hydraulic operated

weights. The lower one is static and it acts like a base for the specimens. The upper one is

movable and the values are taken from that weight only as shown in Figure 12. The testing

process of compression for the polymers are very quick compare to other metal alloys.

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Figure 11. Compression test specimen before test Figure 12. Compression Testing Machine

From various experimental study conducted, cost for every process and material used is also

important.

RESULTS AND DISCUSSION

MECHANICAL TEST RESULTS

This type of tests helps to understand the strength and ductility of specimens developed.

TENSILE TEST

Figure 13. Shows the tensile test specimen after testing.

Figure 13. Tensile test specimen after testing

IMPACT TEST

The test specimen is prepared according to its ASTM standards and Izod Impact Test is

carried out and the results were plotted in the Table 3.

Table 3. Izod Impact Test Results

Impacttest
Trial jol
1 2
2 6
3 2
4 2
5 10
6 2
2 7
8 3
9 4

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The above result values show the results of three impact test specimen. Figure 14. shows the

impact test specimen after tested.

Figure 14. Impact Strength Tested Specimen

COMPRESSION TEST

The test specimen is prepared according to its ASTM standards and compression test is

carried out and the results were shown in the Table 4.

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Table 4. Compression Test Results

CompressionTest

Peak End Breaking

Trial Displacement
Load Displacement Load

1 8.94 2.8 6 4.8

2 7.62 0.3 4.3 3.46

3 7.78 0.3 7.2 3.86

4 8.44 0.2 6.7 3.84

5 7.48 0.8 5.6 3.52

6 9.7 0.6 8.5 4.16

7 9.063 0.4 1.9 3.76

8 9.96 4.4 4.5 4.16

9 9.902 0.8 1.5 4.36

The above result table shows compression strength of the specimens that prepared. Figure 15.

shows the compression test specimen after tested. In Table 5. All the tested results were

tabulated.

Figure 15. Compression Strength Tested Specimen

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Table 5. Tested results

Tria Infill Nozzle Print Tensile Compressi Impact

l Density( Temperatu Orientati strength on strength

%) re on (kn/mm^ strength (kn/mm^

1 30 190 90 0.004 4.18
(°C) 2) (kn/mm^2) 2 2)
2 30 200 0 0.02 3.46 6
3 30 210 180 0.016 3.86 2
4 40 190 0 0.021 3.84 2
5 40 200 180 0.022 3.96 10
6 40 210 90 0.004 4.16 2
7 50 190 180 0.014 3.76 7
8 50 200 90 0.009 4.16 3
9 50 210 0 0.022 4.36 4

TENSILE TEST TAGUCHI ANALYSIS

Figure 16. (a) & (b) shows the taguchi analysis for tensile strength.

Figure 16. (a) Taguchi analysis (b) Tensile strength versus infill density

COMPRESSION TEST TAGUCHI ANALYSIS

Figure 17. (a) & (b) shows the taguchi analysis for compression strength.

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Figure 17. (a) Taguchi analysis (b) Compression strength versus infill density

IMPACT TEST TAGUCHI TEST

Figure 18. (a) & (b) shows the taguchi analysis for impact strength.

Figure 18. (a) Taguchi analysis (b) Impact strength versus infill density

CONCLUSION

Now a days 3D printed component is most widely used for various purposes, but its properties

like Tensile, compression, Impact, etc. can be improved by using of various methods. In this

project work the new combinations are developed and various mechanical tests are done and

obtained results are compared and listed below:

From all the results of mean values of specimens, by using the taguchi analysis method, it

makes the conclusion that at the infill density of 50%, in the nozzle temperature of 200% and

at the print orientation of horizontal position, it can create a good and strong product compare

to other combination. All this test helps in better understanding of components under the

influence of infill density, nozzle temperature and the print orientation.

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