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materials

Article
Mechanical Properties of 3D-Printing Polylactic Acid
Parts subjected to Bending Stress and Fatigue Testing
J. Antonio Travieso-Rodriguez 1, * , Ramon Jerez-Mesa 2 , Jordi Llumà 3 ,
Oriol Traver-Ramos 1 , Giovanni Gomez-Gras 4 and Joan Josep Roa Rovira 3
1 Mechanical Engineering Department, Escola d’Enginyeria de Barcelona Est, Universitat Politècnica de
Catalunya, Avinguda d’Eduard Maristany, 10–14, 08019 Barcelona, Spain; oriol.traver@upc.edu
2 Engineering Department, Faculty of Sciences and Technology, Universitat de Vic—Universitat Central de
Catalunya, C. Laura, 13 Vic, 08500 Barcelona, Spain; ramon.jerez@uvic.cat
3 Materials Science and Metallurgical Engineering Department, Universitat Politècnica de Catalunya,
Escola d’Enginyeria de Barcelona Est, Avinguda d’Eduard Maristany, 10–14, 08019 Barcelona, Spain;
jordi.lluma@upc.edu (J.L.); joan.josep.roa@upc.edu (J.J.R.R.)
4 Industrial Engineering Department, IQS School of Engineering, Universitat Ramon Llull, Via Augusta, 390,
08017 Barcelona, Spain; giovanni.gomez@iqs.url.edu
* Correspondence: antonio.travieso@upc.edu

Received: 25 October 2019; Accepted: 19 November 2019; Published: 22 November 2019 

Abstract: This paper aims to analyse the mechanical properties response of polylactic acid (PLA)
parts manufactured through fused filament fabrication. The influence of six manufacturing factors
(layer height, filament width, fill density, layer orientation, printing velocity, and infill pattern) on the
flexural resistance of PLA specimens is studied through an L27 Taguchi experimental array. Different
geometries were tested on a four-point bending machine and on a rotating bending machine. From
the first experimental phase, an optimal set of parameters deriving in the highest flexural resistance
was determined. The results show that layer orientation is the most influential parameter, followed
by layer height, filament width, and printing velocity, whereas the fill density and infill pattern show
no significant influence. Finally, the fatigue fracture behaviour is evaluated and compared with that
of previous studies’ results, in order to present a comprehensive study of the mechanical properties
of the material under different kind of solicitations.

Keywords: additive manufacturing; 3D printing; fused filament fabrication; flexural properties;


fatigue; PLA

1. Introduction
Manufacturing through fused filament fabrication (FFF) or 3D-printing is a phenomenon that
has drastically changed the way manufacturing is understood, mainly during the last decade [1]. The
interest comes from the clear advantages that this group of technologies presents with respect to
traditional manufacturing technologies; that is, great freedom of design and innovation capacities,
a stronger connection between design and manufacturing, or the ability to manufacture unique
pieces [2]. In addition, additive manufacturing (AM) systems have been easily implemented in
domestic or low-scale manufacturing environments as a cheap and easy manufacturing technology.
Regardless of the rapid expansion of AM, the problem related to the identification and prediction
of the mechanical behaviour and physical characteristics of the final pieces has been the main handicap
for its application in industrial environments or final pieces. This difficulty lies in the fact that the
parameters to be defined during the manufacturing process are numerous and interact with one
another; and, on the other hand, because of the anisotropy of the material, caused by the high influence

Materials 2019, 12, 3859; doi:10.3390/ma12233859 www.mdpi.com/journal/materials


Materials 2019, 12, 3859 2 of 20
Materials 2019, 12, x FOR PEER REVIEW 2 of 21

of the
also filament orientations
originated thanks to thein the manufacturing
difference between the space
bonding[3]. Furthermore,
forces between anisotropy
strands ofalso originated
the same layer
thanks
(intralayer) and between layers (interlayer) [4]. For these reasons, the orientation of the layers is a and
to the difference between the bonding forces between strands of the same layer (intralayer) key
between
parameter layers
to be(interlayer)
defined when [4]. taking
For these intoreasons,
accountthe the orientation of the layers
work conditions of theispiece.
a key parameter to be
defined when taking
According into account
to Bellehumeur the[5],
et al. work
theconditions
mechanicalofresistancethe piece.of parts is the result of the addition
According to Bellehumeur et al. [5], the mechanical
of three factors: the resistance of the filaments, the resistance of the resistance of parts
unionisbetween
the resultfilaments
of the addition
of the
of three
same factors:
layer, andthe theresistance
resistance ofof
thethefilaments, the resistance
union between layers.ofThethe union
inherentbetween filaments
resistance of theoffilaments
the same
layer,
mainly and the resistance
depends on the of the union between
mechanical properties layers.
of the The rawinherent
material resistance
and theofstrength
the filaments
of themainly
joints
depends
depends on onthe themechanical
cohesion properties of the raw This
between filaments. material and the strength
is proportional of the
to the joints depends
thermal energy of on the
cohesion
filaments between
when they filaments.
come intoThiscontact
is proportional
when being to the thermal
placed. Theenergy
unionofisthe filaments
a local sinterwhen they
in which
come
polymer intochains
contact when
are being
shared. placed.
This process Theisunion
applicableis a local
to allsinter
joints,in between
which polymer chains of
layer threads areboth
shared.
the
This
sameprocess
layer and is applicable
different ones.to all joints, between layer threads of both the same layer and different ones.
The authors
authors Gurrala
Gurrala and and Regalla
Regalla [6],[6], Gray
Gray et al. [7], and Zhong et al. [8] agree that the orientation
of the layers must be coincident coincident with the directions of the the expected
expected service loads to optimize the
mechanical
mechanical properties.
properties. In contrast, in compression forces, owing to the buckling effect, the fibres tend
to bend. Therefore, the fibres should be oriented oriented perpendicular
perpendicular to to the
the load
load in
in this
this case
case [9].
[9].
This same
sameeffect
effectofofthetheorientation
orientationofof the layers
the layers ononthethe mechanical
mechanical properties
propertiesof the workpieces,
of the workpieces, has
also
has been
also observed
been observed in otherinprocesses of AM, asof
other processes in the
AM,technology
as in theoftechnology
laminated object manufacturing
of laminated object
(LOM), according
manufacturing to Olivier
(LOM), et al.to
according [10]; selective
Olivier et al. sintering
[10]; selectiveby laser, as reported
sintering by laser, Ajoku et al. [11];
as reported Ajoku or
stereolithography presented by presented
et al. [11]; or stereolithography Quintana et byal. [12].
Quintana et al. [12].
Another parameter with great influence on the mechanical mechanical properties
properties is is the
the height
height of of the
the layer.
layer.
When
When the thelayers
layershavehave a lower
a lowerheight,
height,the parts showshow
the parts an overall better cohesion
an overall betweenbetween
better cohesion layers, because
layers,
the contact
because thesurface
contactissurface
greaterisand the empty
greater and the spaceemptybetween
space filaments is smaller.isThis
between filaments effectThis
smaller. improves
effect
the transport
improves mechanism
the transport of thermal
mechanism of energy,
thermalfavouring
energy, favouringthe welding betweenbetween
the welding wires, as found
wires, in the
as found
work
in theof [9] of [9]
work
On the other hand, the thickness or width of the extruded filament is also a parameter parameter that
significantly influences
influences the the mechanical
mechanical behaviour.
behaviour. It has a great impact on the transport mechanisms
of thermal energy,
energy, which
which will will affect
affect thethe cohesion
cohesion of of the
the threads,
threads, according to the study proposed by
Wang
Wang et et al.
al. [13].
[13].
The printing
printingstrategy
strategydetermines
determines thethe
paths
paths of the
of machine
the machine headheadin theincreation of the piece.
the creation of theWithin
piece.
Within
this this context,
context, the printed the pieces
printed arepieces
composedare composed of two characteristic
of two characteristic zones: thezones:
contour theandcontour and
infill. The
infill. The
outline outline
is the skinisthat
the skin that the
delimits delimits
piecetheand piece and corresponds
corresponds to the outerto theperimeters.
outer perimeters.
The infillTheisinfill
the
is theformed
one one formedby theby the trajectories
trajectories that thethatnozzle
the nozzlefollowsfollows
to filltothe
fillempty
the emptyspace space
that that remains
remains insideinside
the
the contour,
contour, as depicted
as depicted in Figure
in Figure 1. 1.

Figure 1. Section
Figure 1. Section of
of aa piece
piece printed
printed with
with two
two types
types of
of fill
fill patterns.
patterns. Left: honeycomb, right:
Left: honeycomb, right: linear.
linear.

Generally,
Generally, in
in each
each layer,
layer, the
the contour
contour is
is first
first performed
performed followed
followed by by the
the internal
internal filling
filling with
with the
the
selected printing strategy. Each one provides different mechanical properties. In the
selected printing strategy. Each one provides different mechanical properties. In the present work,present work, the
influence of several
the influence patterns
of several shall shall
patterns be studied, as well
be studied, asas different
well infill densities,
as different to assess
infill densities, totheir impact
assess their
on the workpiece
impact flexuralflexural
on the workpiece behaviour.behaviour.
Materials 2019, 12, x FOR PEER REVIEW 3 of 21

The
Materials printing
2019, 12, 3859 velocity is also a modifiable parameter. It can be defined for each printing 3zone, of 20
being independent for the contours, fills, and upper and lower layers. The velocity will be a parameter
of study in this work since it has influence in the process of melting and solidification of the filaments.
The printing
In addition, velocity
it affects the rateis also a modifiable
of extruded parameter. It can be defined for each printing zone,
material.
beingConsidering
independentthe for aforementioned
the contours, fills,baseand ofupper and lower
knowledge layers.
about FFF,The velocity
this paperwill beto
aims a parameter
study the
of study in this work since it has influence in the process of melting and solidification
influence of the manufacturing parameters on the mechanical properties of pieces made of polylactic of the filaments.
In addition, it affects the rate of extruded material.
acid (PLA) manufactured by FFF. Specifically, the flexural mechanical properties of these parts are
Considering
evaluated. the aforementioned
The results obtained are also base of knowledge
compared with theabout
thoseFFF, this paper
obtained aims to study
in a previous studytheby
influence of the manufacturing parameters on the mechanical properties of
Gómez-Gras et al. [14] and Jerez-Mesa et al. [15], performed on the same material subjected to a pieces made of polylactic
acid (PLA)loading
different manufactured
mode. The by FFF.
main Specifically, the flexural
novelty delivered by mechanical
this paper properties of these parts
is that it contributes to are
the
evaluated.
enrichmentThe results obtained
of mechanical are also
behavioural datacompared
regarding with
PLAthe those obtained
material. So far, aninextensive
a previous study
study by
about
Gómez-Gras et al. [14] and Jerez-Mesa et al. [15], performed on the same material
bending properties and their direct comparison to fatigue performance linked to process parameters subjected to a different
loading mode.
has not been Thein
found main novelty delivered
the literature. by this the
For this reason, paper is that
results it contributes
presented to thecomplement
in this paper enrichment
of mechanical
other behavioural
results regarding dataorregarding
tensile PLA material.
fatigue properties, So far,
presented byan extensive
authors study about
in previous bending
references, as
properties and their direct comparison to fatigue performance linked to process
presented above. The makers and users of FFF machines often ask about the best way to manufacture parameters has not
been
their found
parts. inThetheanswer
literature.
shouldFor this reason,
be that the results
printing presented
parameters in this
should be paper
chosencomplement
according to other
the
results regarding tensile or fatigue properties, presented by
expected part behaviour; this paper contributes to enriching that answer. authors in previous references, as presented
above. The makers and users of FFF machines often ask about the best way to manufacture their
parts. The answer
2. Materials should be that printing parameters should be chosen according to the expected part
and Methods
behaviour; this paper contributes to enriching that answer.
In this paper, the flexural mechanical properties of PLA are assessed. The influence of the
2. Materials andparameters
manufacturing Methods in these properties will also be analysed. Therefore, the first experimental
stage explained in this paper comprises a series of four-point bending tests performed on prismatic
In this paper, the flexural mechanical properties of PLA are assessed. The influence of the
test specimens, following the American Society for Testing and Materials (ASTM) D6272-2 standard
manufacturing parameters in these properties will also be analysed. Therefore, the first experimental
[16].
stage explained in this paper comprises a series of four-point bending tests performed on prismatic test
To better understand the influence of the significant parameters, different images of the
specimens, following the American Society for Testing and Materials (ASTM) D6272-2 standard [16].
fractured areas were taken and subsequently analysed. In addition, to complement the fractography,
To better understand the influence of the significant parameters, different images of the fractured
a micro scratch test was performed, which helped to better understand the fracture mechanism of the
areas were taken and subsequently analysed. In addition, to complement the fractography, a micro
pieces.
scratch test was performed, which helped to better understand the fracture mechanism of the pieces.
In a second experimental stage, a fatigue Whöler curve generated through flexural fatigue tests
In a second experimental stage, a fatigue Whöler curve generated through flexural fatigue tests
was drawn to analyse whether the best conditions obtained in the four-point bending tests also derive
was drawn to analyse whether the best conditions obtained in the four-point bending tests also derive
in good fatigue properties.
in good fatigue properties.
2.1. Four-Point Bending Tests
2.1. Four-Point Bending Tests
2.1.1. Specimens
2.1.1. Manufacture
Specimens Manufacture
The design
The design of
of the
the specimens
specimens usedused in
in the
the study
study was
was done
done with
with SOLIDWORKS
SOLIDWORKS®® Research Edition
Research Edition
2019 software (Dassault Systèmes, Vélizy-Villacoublay, France) and the models were
2019 software (Dassault Systèmes, Vélizy-Villacoublay, France) and the models were filleted with Slic3r filleted with
Slic3r software (GNU Affero General Public License) [17]. Subsequently, they were
software (GNU Affero General Public License) [17]. Subsequently, they were manufactured in the manufactured in
the domestic
domestic 3D printer,
3D printer, Pyramid
Pyramid 3Dstudio
3Dstudio XL Single
XL Single Extruder.
Extruder. Their geometry
Their geometry is shown is shown in 2,
in Figure Figure
with
2, with dimensions according to the standard that governs the bending test.
dimensions according to the standard that governs the bending test. All manufactured specimens wereAll manufactured
specimens to
submitted were submitted
a quality to ainquality
control, control,
which they wereinweighed
which they andwere weighed
measured withand measured
a calliper. with a
Therefore,
calliper.
they had Therefore, theybefore
to be validated had totesting
be validated
from a before testingand
dimensional from a dimensional
constructive pointand constructive
of view. point
The resulting
of view. The resulting lengths, widths, and weights were statistically processed, and
lengths, widths, and weights were statistically processed, and those specimens whose descriptors werethose specimens
whose
out descriptors
of the ±2% werewere out ofnot
considered theto±2% wereand
comply considered not to comply
were immediately and were immediately
discarded.
discarded.

Figure 2. Test specimen’s geometry: 80 mm × 10 mm × 4 mm, according to the D6272-02 ASTM standard.
Figure 2. Test specimen’s geometry: 80 mm × 10 mm × 4 mm, according to the D6272-02 ASTM
The material used in the manufacture of the specimens, as discussed above, is PLA. It is a
standard.
biodegradable thermoplastic. The choice of PLA as the study material was based on the fact that it is
Materials 2019, 12, 3859 4 of 20

the most used material in domestic 3D printing. In this case, the selected filament was manufactured
by Fillamentum Company from the Czech Republic. It has a diameter of 3 mm and its extrusion
temperature is around 210 ◦ C. The technical information provided by the manufacturer is indicated
in Table 1.

Table 1. Mechanical properties of polylactic acid (PLA).

Mechanical Property Value


Yield strength 60 MPa
Elongation at break 6%
Tensile modulus 3600 MPa
Flexural strength 83 MPa
Flexural modulus 3800 MPa

2.1.2. Taguchi Experimental Design


To carry out the four-point bending study, the design of experiments (DOE) technique was used.
The design consists of the combination of the printing parameters that are considered most influential
in mechanical behaviour. Six parameters are included in the study, and three levels of each one are
defined (Table 2). They were selected taking into account the bibliography studied, as well as the
experience of previous work of the research group.

Table 2. Parameters and levels used in design of experiments (DOE).

Level
Parameter
1 2 3
Filament width (mm) 0.3 0.4 0.6
Layer height (mm) 0.1 0.2 0.3
Fill density (%) 25 50 75
Printing velocity (mm/s) 20 30 40
Layer orientation X- axis Y- axis Z- axis
Infill pattern Linear Rectilinear Honeycomb
Materials 2019, 12, x FOR PEER REVIEW 5 of 21
Filament width: Determined by the diameters of the extrusion nozzles: 0.3, 0.4, and 0.6 mm.
optimize
It defines the
the manufacturing time. of
volume and surface Inthe
thisextruded
study, the same velocity
threads, was
as well as thedefined
weldingforsurface
all parts of the
between
piece to homogenize
filaments (Figure 3A).its structure.

Figure 3. Schematic representation of the parameters used in the study: (A) filament width and layer
Figure (B)
height, 3. Schematic representation
infill pattern of the parameters used in the study: (A) filament width and layer
and fill density.
height, (B) infill pattern and fill density.
Materials 2019, 12, x FOR PEER REVIEW 5 of 21

optimize the manufacturing time. In this study, the same velocity was defined for all parts of the
piece to homogenize its structure.
Materials 2019, 12, 3859 5 of 20

Layer height: Describes the thickness of each layer and, therefore, the number of layers the printed
piece will have. It affects the volume and surface of the threads, as well as the welding between layers.
The manufacturing time is inversely proportional to the layer height. Thinner layers imply more layers
to print and a longer production time (Figure 3A).
Fill density: Represents the amount of material that is deposited within the contours. It avoids
relative movements between contours and gives robustness to the pieces. It also determines the
distance between the inner threads and affects material consumption (Figure 3B).
Fill pattern: Defines the trajectories that the nozzle follows to fill the empty space within
the contour. Each pattern will create a different interior geometry producing different mechanical
behaviours (Figure 3B).
Orientation: The specimens will be printed in the direction of the three coordinate axes: X, Y, and
Z, as shown in Figure 4. In this way, the stacking of the layers will be done in three different ways
and their behaviour
Figure can representation
3. Schematic be studied. Normally, the stacking
of the parameters used direction is the
in the study: (A) most determinant
filament factor in
width and layer
mechanical
height,behaviour [18]. and fill density.
(B) infill pattern

(a) (b) (c)


Figure4.4.The
Figure Theorientation
orientationofofthe
thelayers’
layers’stacking,
stacking,ininthe
themanufactured
manufacturedspecimens.
specimens.(a)
(a)X-axis
X-axisoriented;
oriented;
(b) Y-axis oriented; (c) Z-axis oriented.
(b) Y-axis oriented; (c) Z-axis oriented.

In this study,
Printing a Taguchi
velocity: L27 DOE
It determines the was used.and
extrusion Thisdeposition
method has beenthreads’
of the appliedvelocity.
successfully in other
The velocity
isstudies
definedconcerning the of
for each part mechanical properties
the piece (inner, of FFF
external pieces [14].
perimeters, Table
inner 3 shows
threads, andanso
orthogonal matrix
on) to optimize
with
the a specific combination
manufacturing of parameters
time. In this used. velocity
study, the same The influence of theseforseparately
was defined as the
all parts of wellpiece
as their
to
interaction will
homogenize be studied.
its structure.
In this study, a Taguchi L27 DOE was used. This method has been applied successfully in other
Table 3. Orthogonal
studies concerning the mechanical propertiesmatrix
of FFFofpieces
Taguchi L27Table
[14]. for the3DOE.
shows an orthogonal matrix
with a specific combination Layer of parametersInfill
used. The Printing
influence of these separately as well as their
interaction Filament
will be studied. LaY-axiser
N° Height Density Velocity Infill
Width [mm] Orientation
[mm] (%) [mm/s]
1 0.3 0.1 25 20 X-axis Rectilinear
2 0.3 0.1 50 30 Y-axis Linear
3 0.3 0.1 75 40 Z-axis Honeycomb
4 0.3 0.2 25 30 Y- axis Honeycomb
5 0.3 0.2 50 40 Z- axis Rectilinear
Materials 2019, 12, 3859 6 of 20

Table 3. Orthogonal matrix of Taguchi L27 for the DOE.

Printing
Filament Layer Height Infill LaY-axiser
N◦ Velocity Infill
Width [mm] [mm] Density (%) Orientation
[mm/s]
1 0.3 0.1 25 20 X-axis Rectilinear
2 0.3 0.1 50 30 Y-axis Linear
3 0.3 0.1 75 40 Z-axis Honeycomb
4 0.3 0.2 25 30 Y- axis Honeycomb
5 Materials 2019,
0.312, x FOR PEER REVIEW
0.2 50 40 Z- axis Rectilinear
6 of 21
6 0.3 0.2 75 20 X- axis Linear
7 6 0.3 0.3 0.30.2 7525 2040 Z-axis
X- axis Linear
Linear
8 0.3 0.3 50 20 X- axis Honeycomb
7 0.3 0.3 25 40 Z- axis Linear
9 0.3 0.3 75 30 Y- axis Rectilinear
10 8 0.4 0.3 0.10.3 5025 2030 X-
Z-axis
axis Honeycomb
Linear
11 9 0.4 0.3 0.10.3 7550 3040 Y-
X-axis
axis Rectilinear
Honeycomb
12 10 0.4 0.4 0.10.1 2575 3020 Z-Y-axis
axis Linear
Rectilinear
13 11 0.4 0.4 0.20.1 5025 4040 X-axis
X- axis Rectilinear
Honeycomb
14 12 0.4 0.4 0.20.1 7550 2020 Y-Y-axis
axis Linear
Rectilinear
15 0.4 0.2 75 30 Z- axis Honeycomb
13 0.4 0.2 25 40 X- axis Rectilinear
16 0.4 0.3 25 20 Y- axis Honeycomb
17 14 0.4 0.4 0.30.2 5050 2030 Y-
Z-axis
axis Linear
Rectilinear
18 15 0.4 0.4 0.30.2 7575 3040 Z-
X-axis
axis Honeycomb
Linear
19 16 0.6 0.4 0.10.3 2525 2040 Y-Y-axis
axis Honeycomb
Honeycomb
20 17 0.6 0.4 0.10.3 5050 3020 Z-axis
Z- axis Rectilinear
Rectilinear
21 18 0.6 0.4 0.10.3 7575 4030 X-axis
X- axis Linear
Linear
22 0.6 0.2 25 20 Z- axis Linear
19 0.6 0.1 25 40 Y- axis Honeycomb
23 0.6 0.2 50 30 X- axis Honeycomb
24 20 0.6 0.6 0.20.1 5075 2040 Z-Y-axis
axis Rectilinear
Rectilinear
25 21 0.6 0.6 0.30.1 7525 3030 X-
X-axis
axis Linear
Rectilinear
26 22 0.6 0.6 0.30.2 2550 2040 Z-Y-axis
axis Linear
Linear
27 23 0.6 0.6 0.30.2 5075 3020 Z-axis
X- axis Honeycomb
Honeycomb
24 0.6 0.2 75 40 Y- axis Rectilinear
25 0.6 0.3 25 30 X- axis Rectilinear
The rest
26 of the parameters
0.6 that
0.3 affect the
50conception
40of the testY-
specimens
axis remained
Linear constant.
27 0.6 0.3 75 20 Z- axis Honeycomb
2.1.3. Experimental Setup
The rest of the parameters that affect the conception of the test specimens remained constant.
The tests were carried out on the Microtest EM2/20 universal electromechanical machine, with a
capacity 2.1.3.
of 20Experimental
kN, displacement
Setup of 300 mm, and a speed range 0–160 mm/min. The force acquisition
was performed The with a load
tests were cell out
carried of 500 N Microtest
on the and a precision of 0.03 N.
EM2/20 universal electromechanical machine, with
Theatest consists
capacity of placing
of 20 kN, the of
displacement specimen
300 mm, andof aaspeed
rectangular cross
range 0–160 section
mm/min. The over two supports and
force acquisition
was
loading it at performed
two points with
bya load
meanscell of
of 500
twoNloading
and a precision of 0.03
rollers; eachN.at an equal distance from the adjacent
support point. TheThe
test consists
specimen of placing
is bent theatspecimen of a rectangular
a constant speed, until cross
thesection over fibres
external two supports
break,andor until the
loading it at two points by means of two loading rollers; each at an equal distance from the adjacent
maximum deformation of the external fibres reaches a 5% elongation. The parameters
support point. The specimen is bent at a constant speed, until the external fibres break, or until the
used in the
experiment are described in the D6272-02 ASTM standard; that is, a support span
maximum deformation of the external fibres reaches a 5% elongation. The parameters used in the of 64 mm and a load
span of 21.3 mm (Figure
experiment 5). in the D6272-02 ASTM standard; that is, a support span of 64 mm and a
are described
load span of 21.3 mm (Figure 5).

Figure 5.Figure 5. Diagram


Diagram of theoffour-point
the four-point bendingtest
bending test method,
method, according to the
according toD6272-02 ASTM ASTM standard.
the D6272-02
standard.
Materials 2019, 12, 3859 7 of 20
Materials 2019, 12, x FOR PEER REVIEW 7 of 21

The deflection value will be obtained through image processing. High-definition video capture
is planned for all tests. ThatThat way, the displacement will be obtained through image processing, by
following a marker painted
following a marker painted on on the
the lower
lower fibre
fibre of
of the
the specimen.
specimen. TheThe displacement
displacement willwill be
be determined
determined
to calculatethe
to calculate theoverall
overalldeflection
deflection (Figure
(Figure 6). 6).
OnOn the the other
other hand, hand, the force
the force appliedapplied
by theby the loading
loading rollers
rollers
will be will be measured
measured withcell.
with a load a load
Thecell. The objective
objective of data processing
of data processing is tothe
is to create create the stress–strain
stress–strain curve of
curve of the specimens
the specimens [19]. From [19].
theFrom the obtained
obtained curve, thecurve, the following
following results
results will will be extracted:
be extracted: Young's
Young’s modulus
modulus
(E), elastic(E), elastic
limit limit
(Rp0.2 (Rp0,2), maximum
), maximum strength (σ strength (σmax
max ), and ), and maximum
maximum deformation
deformation (ε). (ε).

Figure 6.
Figure The installation
6. The installation used
used to
to perform
perform the
the four-point
four-point bending
bending tests.
tests.
The test method used contemplates two different types, which differ in the test speed according to
The test method used contemplates two different types, which differ in the test speed according
the behaviour of the test piece.
to the behaviour of the test piece.
Type A. Used in test specimens that break with little deflection.
Type A. Used in test specimens that break with little deflection.
Type B. Used in the test specimens that absorb large deflections during the test.
Type B. Used in the test specimens that absorb large deflections during the test.
The Type A test will end when breakage is detected in the outer fibres of the test pieces, and the
The Type A test will end when breakage is detected in the outer fibres of the test pieces, and the
Type B test will end when specimens break or the deflection D = 10.9 mm, according to measurements
Type B test will end when specimens break or the deflection D = 10.9 mm, according to measurements
of the specimens and the parameters used.
of the specimens and the parameters used.
A previous experimental testing was performed to validate the adequacy of the described method.
A previous experimental testing was performed to validate the adequacy of the described
From these experiments, it was detected that specimens printed in the direction of the Z-axis do not
method. From these experiments, it was detected that specimens printed in the direction of the Z-axis
admit deflection, and present brittle failure, while the specimens printed in the direction of the X- and
do not admit deflection, and present brittle failure, while the specimens printed in the direction of
Y-axes admit large deflections. The summary of the test types can be seen in Table 4.
the X- and Y-axes admit large deflections. The summary of the test types can be seen in Table 4.
Table 4. Test parameters.
Table 4. Test parameters.
Concept Test Type A Test Type B
Concept Test Type A Test Type B
Specimen’s orientation Z X and Y
Specimen’s
Test speed
orientation 1.9 mm/min Z X
19and Y
mm/min
Test speed When break appears in the
1.9 mm/min 19 or
mm/min
End of test When breaks deflection = 10.9 mm
external fibres
When breaks or
When break appears in the
End of test deflection = 10.9
2.1.4. Data Analysis external fibres
mm
The data analysis was processed by following the steps described as follows:
2.1.4. Data Analysis
1. Separation of the frames of the High Definition videos of each test. The camera used registered
The data analysis
the image was processed
at approximately byThe
60 fps. following the steps
tests lasted described
between as 2follows:
45 s and min, so, in each of the 108
1. Separation of the frames of the High Definition
tests, between 2700 and 7200 frames were processed.videos of each test. The camera used registered
the image at approximately 60 fps. The tests lasted between 45 s and 2 min, so, in each of the 108
tests, between 2700 and 7200 frames were processed.
Materials 2019, 12, 3859 8 of 20

Materials 2019, 12, x FOR PEER REVIEW 8 of 21


2. Calculation of the specimen’s deflection through the frames. Position markers were painted
2. Calculation
on the outeroffibre
the specimen’s deflection
of the specimen, through
where the frames.
the maximum Position markers
deflection occurs, andwereonpainted on
the static
the outer
rollers fibre of
(Figure theThe
7A). specimen, where
difference the maximum
between the final deflection occurs,
position and and onone,
the initial the between
static rollers
the
(Figure 7A). The difference between the final position and the initial one,
most displaced marker of the specimen and the markers on the static rollers, is considered between the most
the
displaced
maximum marker
deflectionof (Figure
the specimen
7B). Thisand the was
analysis markers on thethrough
performed static rollers, is considered
a self-designed MATLAB the®
maximum deflection (Figure 7B). This
code (version 2018) with image processing functions. analysis was performed through a self-designed
MATLAB® code (version 2018) with image processing functions.
The calculation
The calculation of of the
the stress
stress that
that is
is generated
generated inin the
the specimen
specimen at
at each
each moment
moment by by means
means of of
Equation (1) is
Equation 1 is as follows:as follows:
PL
S=𝑃𝐿bd2 , (1)
𝑆= , (1)
where 𝑏𝑑
where
S = Stress
S = Stress in thein the outermost
outermost fibre (MPa)
fibre (MPa)
P = Applied load (N)
P = Applied load (N)
L = Distance between support rollers (64 mm)
L = Distance between support rollers (64 mm)
b = Width of the specimen (10 mm)
b = Width of the specimen
d = Thickness (10 mm) (4 mm)
of the specimen
d = Thickness of the specimen (4 mm)
3. Analysis of the stress–strain curve obtained to extract the study parameters.
3. Analysis of the stress–strain curve obtained to extract the study parameters.

Figure 7.
Figure Schematic representation
7. Schematic representationof
ofthe
thedata
datacollection
collectionprocess
processduring
duringthe tests.
the (A)
tests. Initial
(A) position
Initial of
position
markers;
of (B)(B)
markers; final position
final (red
position crosses)
(red andand
crosses) initial position
initial (green
position crosses)
(green of the
crosses) markers.
of the markers.
2.2. Fractography and Scratch Test
2.2. Fractography and Scratch Test
In order to analyse the influence of the parameters that were significant, a SMZ-168 MOTIC stereo
In order to analyse the influence of the parameters that were significant, a SMZ-168 MOTIC
microscope was used to observe the fractures surfaces. The most interesting fracture phenomena
stereo microscope was used to observe the fractures surfaces. The most interesting fracture
were photographed with a MOTICAM 2300 camera. Both equipment were manufactured by Motic® ,
phenomena were photographed with a MOTICAM 2300 camera. Both equipment were
Xiamen, China.
manufactured by Motic®, Xiamen, China.
Also, micro scratch tests were conducted in a scratch tester unit (CSM-Instruments, Needham, MA,
Also, micro scratch tests were conducted in a scratch tester unit (CSM-Instruments, Needham,
USA) (Figure 8A) using a sphere-conical diamond indenter with a radius of 200 µm. Tests were done
MA, USA) (Figure 8A) using a sphere-conical diamond indenter with a radius of−1200 µm. Tests were
under a linearly increasing load, from 0 to 70 N, at a loading rate of 10 mm·min and in an interval
done under a linearly increasing load, from 0 to 70 N, at a loading rate of 10 mm·min−1 and in an
length of 5 mm, according to the ASTM C1624-05 standard [20]. Figure 8B shows the two different
interval length of 5 mm, according to the ASTM C1624-05 standard [20]. Figures 8 B shows the two
scratches per specimen that were carried out in order to observe the reproducibility of the induced
different scratches per specimen that were carried out in order to observe the reproducibility of the
induced damage. Furthermore, the micro scratch tests were conducted in the longitudinal and
transversal printing direction to observe the main plastic deformation mechanisms induced. Surface
Materials 2019, 12, 3859 9 of 20

damage.
Materials Furthermore,
Materials2019,
2019, 12,xxFOR
12, FORPEERthe
PEER micro scratch tests were conducted in the longitudinal and transversal
REVIEW
REVIEW 99 of
of 21
21
printing direction to observe the main plastic deformation mechanisms induced. Surface damage
damageduring
damage
induced induced
induced during
during
scratch scratch
scratch
tests tests
wastests wasobserved
was
observed observed byaascanning
by
by a desktop desktopscanning
desktop scanning electronmicroscopy
electron microscopy
electron microscopy (SEM)
(SEM)
(SEM) Phenom
Phenom
Phenom
XL XLfrom
XL fromThermoFisher
from ThermoFisher ThermoFisher Scientific(Waltham,
Scientific Scientific
(Waltham, (Waltham, MA,
MA, USA)MA, USA)
USA)
(Figure (Figure8C).
(Figure
8C). 8C).

Figure
Figure 8.8.Micro
Figure8. Microscratch
Micro scratchtest.
scratch test.(A)
test. (A)scratch
(A) scratchtester
scratch testerunit;
tester unit;(B)
unit; (B)specimen;
(B) specimen;(C)
specimen; (C)scanning
(C) scanningelectron
scanning electronmicroscopy
electron microscopy
microscopy
(SEM) ThermoFisher
(SEM)ThermoFisher
(SEM) Scientific
ThermoFisherScientific Phenom
ScientificPhenom XL.
PhenomXL.XL.

2.3. Fatigue Test


2.3.Fatigue
2.3. FatigueTest
Test
To complete this study, it is proposed to analyse, in a second experimental stage, how cylindrical
Tocomplete
To completethis
thisstudy,
study,ititisisproposed
proposedto toanalyse,
analyse,ininaasecond
secondexperimental
experimentalstage,
stage,how
howcylindrical
cylindrical
specimens behave when manufactured through the optimal parameter set found in the previous study,
specimens behave when manufactured through the optimal parameter
specimens behave when manufactured through the optimal parameter set found in the previous set found in the previous
subjected to a rotating fatigue test. This will also allow the comparison with other values previously
study, subjected
study, subjected to
to aa rotating
rotating fatigue
fatigue test.
test. This
This will
will also
also allow
allow the
the comparison
comparison withwith other
other values
values
obtained for the same material using other printing conditions [14].
previouslyobtained
previously obtainedfor forthe
thesame
samematerial
materialusing
usingother
otherprinting
printingconditions
conditions[14].
[14].
The rotating bending fatigue test consists of applying a variable bending moment on a cylindrical
The rotating
The rotating bending
bending fatigue
fatigue test
test consists
consists ofof applying
applying aa variable
variable bending
bending moment
moment on on aa
test piece of known dimensions that rotates on its own axis. In this way, alternative tensile and
cylindricaltest
cylindrical testpiece
pieceofofknown
knowndimensions
dimensionsthat thatrotates
rotateson onits
itsown
ownaxis.
axis.In
Inthis
thisway,
way,alternative
alternativetensile
tensile
compressive stresses are generated in the external fibres in each rotation. The test was carried out
and compressive
and compressive stresses
stresses are
are generated
generated in in the
the external
external fibres
fibres in
in each
each rotation.
rotation. The
The test
test was
was carried
carried
on printed cylindrical specimens like the one shown in Figure 9. For the fabrication of the fatigue
outon
out onprinted
printedcylindrical
cylindricalspecimens
specimenslike likethe
theoneoneshown
shownin inFigure
Figure9. 9.For
Forthe
thefabrication
fabricationof
ofthe
thefatigue
fatigue
specimens, the same 3D printer was used.
specimens,the
specimens, thesame
same3D 3Dprinter
printerwas wasused.
used.

Figure 9. Dimensions of the test specimens used in the fatigue test.


Figure9.9.Dimensions
Figure Dimensionsof
ofthe
thetest
testspecimens
specimensused
usedin
inthe
thefatigue
fatiguetest.
test.
Materials 2019, 12, 3859 10 of 20

3. Results and Discussion

3.1. Four-Point Bending Test


Table 5 shows the results, for each printing configuration, of the stress-strain curve as the average
results of the five repetitions and their standard deviation.

Table 5. Average results and standard deviations of the material properties. E: Young’s modulus,
Rp0.2 : yield strength, σmax : maximum strength, ε: maximum deformation, Std: standard deviation for
each property.

Rp0.2 σmax
# E (GPa) Std Std Std ε Std
(MPa) (MPa)
1 2.36 0.18 53.8 3.19 64.2 8.18 4.72 1.16
2 3.06 0.07 83.5 0.95 96.0 2.98 4.90 0.64
3 1.79 0.03 11.8 1.74 11.8 1.74 0.70 0.13
4 2.74 0.03 69.7 4.10 79.0 4.97 4.68 1.10
5 1.23 0.10 7.92 1.58 7.96 1.58 0.81 0.24
6 2.71 0.03 60.1 3.09 80.8 2.36 5.85 0.50
7 0.59 0.05 6.71 1.76 6.7 1.76 1.20 0.22
8 2.78 0.11 60.6 3.45 64.1 4.43 3.37 0.32
9 2.81 0.06 65.1 3.61 79.2 6.11 4.91 0.59
10 2.29 0.29 37.1 4.04 37.1 4.04 1.64 0.05
11 3.34 0.19 67.9 3.16 83.7 4.53 4.57 0.17
12 3.69 0.08 95.3 4.26 120.0 1.38 5.34 0.20
13 2.41 0.07 50.2 6.97 72.3 8.23 5.72 0.18
14 3.45 0.33 85.0 3.67 104.6 2.16 4.98 0.17
15 2.07 0.21 26.2 3.34 26.1 3.34 1.49 0.41
16 3.19 0.06 73.4 1.15 83.8 3.87 4.09 0.36
17 1.20 0.09 10.6 1.60 10.6 1.60 1.02 0.13
18 1.44 0.27 26.7 3.25 35.7 4.11 5.09 0.74
19 3.61 0.07 87.4 2.53 95.5 7.35 3.73 0.72
20 3.02 0.27 43.4 3.64 43.5 3.64 1.50 0.12
21 3.23 0.02 70.8 3.51 93.1 4.52 5.09 0.22
22 2.33 0.25 21.3 3.22 21.4 3.22 0.53 0.60
23 2.85 0.19 63.4 6.54 86.4 3.27 5.36 0.64
24 3.70 0.14 90.8 2.28 109.5 4.70 5.11 0.95
25 1.90 0.08 44.0 5.16 60.4 4.43 6.21 0.28
26 2.96 0.15 75.2 3.49 86.7 8.68 4.54 1.56
27 2.30 0.15 25.3 6.61 25.4 6.61 0.91 0.61

An analysis of variance (ANOVA) was performed on the dataset included in the Taguchi
experimental array, for each parameter that describes the mechanical behaviour of the evaluated
specimens. To validate the statistical relevance of the parameters included in the model, the p-value
associated with the ANOVA was compared to a significance level of 5%.
One of the first observations derived from the experimental testing is that specimens printed
in the Z-axis direction presented fragile failure, as their failure mode was governed by the lower
resistance between layers deposited vertically, thus with a lower neck growth area between them. For
that reason, the elastic limit (Rp0.2 ) associated with these specimens was by default considered equal to
their maximum strength (σmax ). This approach was necessary to perform the statistical analysis, and
allows the brittle behaviour to be included in the statistical analysis.
Alongside the yield limit and the maximum strength, the Young’s modulus and maximum
deformation were considered as response variables to analyse the influence of the different parameters
in the statistical study. The following subsections describe the influence of the different parameters on
the considered mechanical properties.
Materials 2019, 12, x FOR PEER REVIEW 11 of 21

parameters in the statistical study. The following subsections describe the influence of the different
Materials 2019, 12, 3859 11 of 20
parameters on the considered mechanical properties.

3.1.1. Young’s Modulus


specimens oriented along the Z-axis direction present the lowest
As a predictable result, the specimens
orientation defined as the
rigidity of all, owing to their described brittle behaviour, and thus can be orientation
most influential parameter (Figure 10A). The highest deformation module in the elastic regime is
defined by an orientation of the fibres along the Y-axis direction, because of the different pattern
direction with
deposited in this direction with regards
regards to
to the
the X–axis
X--axisorientation.
orientation.

Figure 10.
Figure Main effects
10. Main effects of
of (A)
(A) means
means and
and (B)
(B) interactions
interactions on
on Young’s
Young's modulus.
modulus.

On
On the
the other
other hand,
hand, anan increase
increase in in the
the value
value of Young’s modulus
of Young's modulus occursoccurs whenwhen the
the filament
filament width
width
increases,
increases, probably because of the higher inertia of the single filaments that restrict bending.
probably because of the higher inertia of the single filaments that restrict bending. This
This
effect
effect of higher inertia of the surface is also achieved by decreasing the layer height, as it derives in
of higher inertia of the surface is also achieved by decreasing the layer height, as it derives in aa
higher
higher value
value of of Young’s
Young'smodulus.
modulus.This Thiseffect
effectcould
couldbe berelated
relatedtotothethefact
factthat
thatporosity
porosityisisdecreased
decreased byby
a
lower layer height (and, complementarily, stiffness is increased). Following
a lower layer height (and, complementarily, stiffness is increased). Following the same line, the the same line, the printing
velocity
printingproves
velocity toproves
increase tothe stiffness
increase theofstiffness
the specimen
of the as it is lower,
specimen as itprobably
is lower,again by the
probably increase
again of
by the
the overall
increase of stiffness.
the overall stiffness.
Of
Of all the
all the tested
tested parameters,
parameters, both both thethe fill
fill density
density and
and the
the infill
infill pattern
pattern hadhad aa negligible
negligible impact
impact
(p-value of the ANOVA test > 5%) and no clear trend, which seems
(p-value of the ANOVA test > 5%) and no clear trend, which seems to disagree with the previous to disagree with the previous
analysis.
analysis. However,
However, itit mustmustbe beconsidered
consideredthat thatthethesmall
smallsize
sizeofofthe specimens
the specimens was
wasderived
derived in in
a lack of
a lack
filling, and the geometry was composed basically of boundary layers that
of filling, and the geometry was composed basically of boundary layers that have relegated the infillhave relegated the infill to a
second plane
to a second in this
plane in experimental
this experimental campaign.
campaign.
Figure
Figure 10B shows that no significantinteraction
10B shows that no significant interactionamongamongparameters
parameters is is
observed,
observed,as as
thethe
p-values
p-valuesof
them
of themareare
all all
greater
greaterthan 0.05.
than 0.05.
3.1.2. Yield Strength
3.1.2. Yield Strength
Figure 11 shows the influence of the printing parameters on the elastic limit. Again, the layer
Figure 11 shows the influence of the printing parameters on the elastic limit. Again, the layer
height and the infill pattern do not show a significant influence. The effect of the other parameters
height and the infill pattern do not show a significant influence. The effect of the other parameters on
on the response follows the same pattern as in the case of Young’s modulus. The most influential
the response follows the same pattern as in the case of Young's modulus. The most influential
parameter again is the printing orientation. With the Y-axis orientation, the highest elastic limit is
parameter again is the printing orientation. With the Y-axis orientation, the highest elastic limit is
achieved, while the Z-axis orientation shows the lowest one. In addition, with the X-axis orientation,
achieved, while the Z-axis orientation shows the lowest one. In addition, with the X-axis orientation,
an intermediate value is achieved with respect to the other printing orientations. The layer height has
an intermediate value is achieved with respect to the other printing orientations. The layer height has
an influence somewhat higher than that of the filament width, but in the opposite way; as the layer
an influence somewhat higher than that of the filament width, but in the opposite way; as the layer
height decreases or the filament width increases, the elastic limit increases. Although the printing
height decreases or the filament width increases, the elastic limit increases. Although the printing
velocity has low relevance, a trend is observed: when the velocity decreases, the elastic limit increases.
velocity has low relevance, a trend is observed: when the velocity decreases, the elastic limit increases.
When analysing the interactions between the different parameters, it is concluded that there is no
significant interaction, as the p-values in each case are much higher than 0.05. The same happens for
the rest of the parameters. This is positive because it means that the influence of the parameters on the
response is independent of each other, at least in the ranges of values analysed.
Materials 2019, 12, 3859 12 of 20
Materials 2019, 12, x FOR PEER REVIEW 12 of 21

Figure 11.
Figure Main effects
11. Main effects of
of means
means for
for yield
yield strength.
strength.

3.1.3. Maximum Strength


When analysing the interactions between the different parameters, it is concluded that there is
The behaviour
no significant of the parameters
interaction, follow
as the p-values the same
in each case pattern
are much as higher
the elastic
thanlimit case
0.05. The(Figure 12). The
same happens
layer orientation is still the parameter with the greatest influence on the mean value, followed
for the rest of the parameters. This is positive because it means that the influence of the parameters by the
layer
on theheight, filament
response width, andof
is independent printing velocity,
each other, withinless
at least theinfluence.
ranges of Fill density
values and infill pattern do
analysed.
Materials
not have2019, 12, x FOR PEER
a statistically REVIEW influence.
significant 13 of 21
3.1.3. Maximum Strength
The behaviour of the parameters follow the same pattern as the elastic limit case (Figure 12). The
layer orientation is still the parameter with the greatest influence on the mean value, followed by the
layer height, filament width, and printing velocity, with less influence. Fill density and infill pattern
do not have a statistically significant influence.

Figure 12. Main effects of means for maximum strength.


Figure 12. Main effects of means for maximum strength.

3.1.4. Maximum Deformation


Figure 13 reveals that the only significant parameter is orientation. The X-axis and Y-axis
orientations cause the greatest elongation and the Z-axis orientation causes the smallest one. Filament
width, layer height, fill density, and printing velocity do not present any pattern or proportionality.
Materials 2019, 12, 3859 13 of 20
Figure 12. Main effects of means for maximum strength.

3.1.4. Maximum Deformation


Figure 13 reveals
reveals that
that the
the only
only significant
significant parameter orientation. The X-axis and Y-axis
parameter isis orientation.
orientations
orientations cause the greatest elongation
greatest elongation and and the Z-axis orientation
orientation causes
causes the smallest
smallest one.
one. Filament
width,
width, layer
layerheight,
height,fill
filldensity,
density,and
andprinting
printingvelocity
velocitydodo
notnot
present anyany
present pattern or proportionality.
pattern The
or proportionality.
honeycomb
The honeycomb fill pattern produces
fill pattern the least
produces theeffect.
leastRegarding the signalthe
effect. Regarding S–N, the only
signal S–N,robust parameter
the only robust
is again theisorientation.
parameter again the orientation.

Figure 13.
Figure Main effects
13. Main effects of
of means
means for
for maximum
maximum deformation.
deformation.

3.1.5. Summary
In Table 6, a summary of the analysis of the influence of each parameter under study on the
different mechanical properties studied can be seen. More green checks indicate that the factor is
more influential on the response. Three checks indicates that p-value < 0.01, two checks indicate that
0.01 < p-value < 0.04, one check indicates that 0.04 < p-value < 0.05. The red cross is assigned to the
parameters that are not statistically significant (p-value > 0.05). The orientation is the most influential
parameter in the zone of both the elastic and plastic behaviour of the pieces tested. The layer height
and the filament width are also parameters that influence all of the properties studied, except for the
maximum deformation. The same thing happens with printing velocity, but to a lesser extent. In
Table 7, the optimum levels of each parameter are shown.
different
more influentialmechanical on the properties
more response.
parameter influential instudied
Three
the on
zone different
can
the
checks
more be
ofresponse.
both seen.
mechanical
influential
indicates More
the Threeelasticthat
on the green
properties
checks
more
p-value
maximum
and checks
response.
influential
indicates
plastic < 0.01, studied
indicate
Three
deformation.
behaviour two
that
on the can
checks
checks that
p-value be
response.
of The
thethe
seen.
indicates
indicate factor
<pieces
0.01,
same More
Three two
thatis checks
that
thing
tested. green
checks
p-valueThechecks
happens indicates
indicate
layer< 0.01,
with indicate
heighttwo
that
that thatv
check
printingp-val
parameters
0.01 < p-value
parameters
parameter inthat
that
the are
< 0.04,
are
zone not
parameters
0.01
one
not statistically
< both
parameters check
p-value
statistically
parameter
of the
inthat
thatthe significant
indicates are
<elastic
0.04,
significant
are zone not
parameters
0.01
notone
that statistically
parameters (p-value
< both
check
p-value
0.04
statistically
parameter
and of (p-value
plastic <in
thethat
that >significant
indicates
p-value are
<elastic0.05).
0.04,
>significant
are
behaviour
the 0.05).
zone not
parameters
<and
notone
and The
that
Thestatistically
0.05.
parameter
ofofthe (p-value
check
both orientation
0.04 The
plastic
the <in
filament
statistically
(p-value
orientation that
indicates
pieces
the red
p-value
behaviour
the >significant
elastic are
0.05).
crossisnot
width
>significant
0.05).
is
tested.
zone <the
thethat
and The
of statistically
most
is0.05.
are
The
ofmost
The (p-value
both orientation
assigned
0.04The
also
(p-value influential
orientation
plastic
the layer <parameters
red
p-value
influential
pieces
the to >>significant
behaviour
height
elastic 0.05).
cross
the is the
0.05).
is
tested. <the
and The
is0.05.
The most
that
most
of
The (p-value
orientation
assigned The influential
influence
orientation
plastic
the redto
influential
layerpieces >cross
behaviour
height 0.05).
the is the
all
is
tested. the
ofisThem
as
the
m
of
Th
more
0.01 <influential
p-value < on 0.04,the
0.01 response.
one < check
p-value Three
indicates
< 0.04, checks
more
0.01
one
that <influential
indicates
check
p-value
0.04 < indicates
p-value
< that
on0.04, the
p-value
0.01<
Table
and the filament width are also parameters that influence all of the properties studied, except for response.
one
that
0.05.
< check <
p-value
0.04
7, The
the 0.01,
< Three
indicates
red
p-value
optimum< two 0.04,
crosschecks
checks
<one
that
is
0.05.
levels indicates
indicate
assigned
check
0.04 The
of <
eachindicates
red
p-value
to that
that
cross
the
parameter p-value
< that
is0.05.
assigned
0.04
are <
The 0.01,
< red
shown. two
p-value
to cross
the checks
< is0.0a
parameter
parameters
parameter
and the in
that
in
filament the
the arezone
zone
widthparameter
not
and of
parameters
of are both
statistically
parameter both
the also the
in
thethat
in
filament the
theelastic
elastic
parameters zone
significant
are zone
width parameter
not and of
parameters
parameter
and
and of are both
plastic
statistically
(p-value
both
thatplastic
the also the
in
that
the
in
influence
filament behaviour
the
elastic
behaviour
the
elastic
parameters zone
>significant
are0.05).
zone
width
all parameter
not and
and
and
of of
The
maximum
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distance
density
changing is
depend
between
and
is, of
we
could
regardless
which
between
100%
which
more
the
between
bonding
in
could
infill
between
derivesthe
bonding
in
the between
the
reduction.to
infill
mechanical
is
effect
ondensity
bonding
filaments
be
is of
same
the
three
layers,
addforces
related
the
filaments
in
any
same
the
conspicuous strength
density
ofthe
other
aforces
filaments
direct
layer,
distance
filaments
direct
layer,
That loss
changing
main
ofis
between
and
second
isto
is,
more
of the
which
in
between
value,
which
more
aspects,
between
bonding
fact
between
the
bonding
in
the the
filaments
conspicuous
issame
hence
infillis
effect same
the
the
conspicuous
namely,
layers,
forces
explaining
filaments
filaments
density
of direct
ofbetwee
layer,
strength
the
directlack
layer,
and
changing
is
thebo
whic
the
la
ofinreit
betw
whic
more
properties
thebending
same layer. of filaments, the the
Decreasing
when same bonding
the layer.
reducing infill forces
Decreasing
density
from properties
the between
100% derives
same the of
to layer.
any layers,
filaments,
infill
in theDecreasing
density
other lossand
the ofbonding
value, the
derives
same
bonding
results,bonding
the
hence layer. forces
infill
in strength
the
which
the forcesbetween
Decreasing
density
loss
lackcould of between
between
of derives
bonding
bethe
relevancefilaments layers,
infill
filaments
related in strength
the
ofdensity
toof and
losstheof
decreasing bonding
between
derives
bonding
fact that forces
filaments
it from in strength
the
bending 75% between
loss of
betw
speci bo
fact that
effect
of
effect
when of infill
the same
of infill
reducing specimens
layer,density
density
from effect
regardless
of the
effect
when are
reduction.
oftoof
same
reduction.
100% of of
infill
infill
reducing any reduced
the
layer,That
density
distance
That
density
other
from is,
regardless
of
is, dimensions,
effect
the
effect
when reduction.
the effect
of
between
same
reduction.
value,
100% toof
effect
of infill
the
infill
reducing
hence any of
layer,
of That
density
filaments
That
thedensitymeaning
changing
distance
changing
other
from
lack is,
effect
regardless
to
is,
when the
value,reduction.
in
25%.
the infill
between
the
reduction.
100%
of infillthat
effect
of
effect
relevance ofinfill
same the
Furthermore,
reducing
hence
to their
density
of
density
any of That
density
That
the changing
filaments
layer,
distance
changing
other
of from mechanical
lackis
is,
is
is,
decreasing more
the
which
we
more
value, reduction.
in
the
100%
of infill
effect
between
the
could
infillconspicuous
isitsame
effect the
conspicuous
relevance
hence
to any
from behaviour
density
addof
density
of That
the changing
filaments
direct
layer,
other
of alack
changing
75% is
is,
second
is more
the
which
more
decreasing
value,
of isinfill
infill
effect
inrelevance
the
fact conspicuous
isitsame
hence thedensity
conspicuous of
density
from changing
direct
explaining
thelayer,
of 75%
lackis which
is more
the
more
decreasinof re lai
the
of thesame same layer. Decreasing
layer, to the the
regardless
of 25%. same ofinfill
the
layer,
Furthermore, density
distance the
regardless
ofwe derives
same
the between
same
could layer.
ofin thetheDecreasing
layer,
add aloss
filaments
distance ofofthe
regardless
second bonding
in the
between
the
same
fact ofinfill
same strength
the
layer,
explaining density
filaments
layer,
distance between
regardless
the derives
whichinbetween
lacktheisof filaments
ininfluence
same
the the the
filaments
direct loss
layer,
distance ofwhich
of bonding
in between
theisdensity
infill same
the strength
filaments
direct on betw
layer, whicin t
governedwhen
effect
when
tothe by
25%. of their
reducing
infill
reducing skin
Furthermore, from
density
from and,
when
100%
effect
when
100%
towe to
reduction.
25%. of a much
reducing
to
reducing
to
could any
infill
any
Furthermore,That lesser
other
from
density
other
from
adddistance is,
a second when
value,
100%
effect
the
when
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100%
towe extent,
reduction.
25%. reducing
hence
to
effect
of
reducing
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infill
anythe
of
Furthermore, the
That
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explaining
add infill,
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otherfrom
density
fromlack
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a second thewhich
when
value,
100%
of
the
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to100%
of
the
we relevance
reduction.reducing
hence
infill
results,to
effect
relevance
25%.lack hence
to
could
fact isany
any only
density
of the
which
Furthermore,
of the
explaining
add other
of
That
changing
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of
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conspicuous
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related
from ofa the
the few
other
of 75%lack
changing
of to
75%lackislayers.
decreasing
value,
the of
more
decreasingof factrelevance
hence
infill it from
conspicuous
that
relevance it density
from the
of
bending
of 75%
lack
decreasin
75% is of
more
speci
decreasin re
of
effect same
of infill layer, regardless
density effect
the of of
reduction.
results, the
infill That
which density of
is, the
effect
could the between
same
reduction.
be effect
ofrelated
infilllayer,
filaments
of That toregardless
density
changing is,
effect
the in
the the
reduction.
fact infill
effect
ofthatofsame the
infill
density
ofThat
bending layer,
distance
density
changing is,which
is more
the between
reduction.
specimens infillisof
effect
density
explaining
the
conspicuous
add
influence
filaments
density
of
are direct
That
a onsecond
changing is
the
is, more
of reduced ininfill
the
lack
factsame
the
infill
effect
of
density
explaining
conspicuous
influence
of layer,
density
dimensions,
on which
changing
the in
is more
la
i
to
when
to
The
the 25%.
25%. Furthermore,
reducing
Furthermore,
manufacturing
results, whichfromcouldto
when
to
the we
100%
we 25%.
25%. could
could
orientation
results,
be Furthermore,
reducing add
toFurthermore,
any add
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plays
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from second
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we25%.
25%.
vital
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be Furthermore,
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be that of
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ofexplaining
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itdimensions,
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related of
influence
of 75%aofon
second
lack
decreasing
on
specimens,
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are to the
of
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of
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the infill
lack
fact
relevance
infill
lack
specimens that of
density
ofexplaining
influence
itdimensions,
from
density of75%
influence
bending
are onreduced
the
decreasing
ofon of in
of
speci in
la
effect
whenof infill density
reducing fromwhen reduction.
100% to anyThat
reducing other
from is,
effect
the effect
when
value,
100% of toinfill
reducing
hence any ofthedensity
changing
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lackwhen reduction.
value,
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of infill
relevance
reducing
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to any density That
the
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is,value,
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decreasing therelevance
100%
of effect
conspicuous
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of 75%lack
decreasing
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of relevance it density
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specimens
fact could
fact
be that
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of which
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related add
influence
bending
are of
tosecond
to could
reduced
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of
reduced
the fact be
infill
lack
specimens
fact fact that
dimensions,
that related
of
density bending
are filaments
explaining
influence
dimensions, bending
are ofof
to reduced
the
onreduced
thespecimens
of fact
lackthat
infill
specimens dimensions,
of
densitybending
are of
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speci
onreduced
of inf
when
to 25%. reducing
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add alacksecond
to100%
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toFurthermore,
any other
explaining
add of adecreasing
influence area
value,
second the
of
weinfill
lackbetween
hence
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fact it of from
density the75%
explaining
add
influence alack
on
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lack
fact of density
explainingof decreasing
influence on the of inla
the results, which could the results,
be related which to could
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bethat related which
bending to couldthespecimens
fact bethat related bending
are of to reduced
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are of reduced specimens dimensions,are of reduced
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to
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fact that density
dimensions,
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are of obtained
onreduced
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specimens
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dimensions,bending
are of reduced of inf
speci
when the
the results,
specimens which arecouldsubjected be related to fatigueto the thefact results,
tests, that where which
bending layer could
specimens
heightbe related isare theof tomostreduced
the fact that
influentialdimensions, bending parameter specimens are of reduced
owing to the fact that the limiting factor here is the prevention of crack propagation, and not bearing
stress itself [9].

3.2. Fractography and Scratch Test


It was already noted that the main factor that determines the strength of the specimens is the
orientation of the stacking layers. In Figure 14, the outlooks of the fracture section of some printed
specimens in the different directions of the coordinate axes are compared. The specimens printed
along the X-axis direction (Figure 14A) or along the Y-axis direction (Figure 14B) have a slight ductile
behaviour with high elongation, good flexural strength, and high rigidity. This reaction is caused by the
filaments being aligned with the main stress direction. The resistance depends on the strength of the
intra-layer bond and the strength of the filaments. The stiffness and flexural strength are slightly higher
in the Y-axis orientation specimens. The reason is once again the arrangement of the layers. Although
the two orientations have the filaments parallel to the direction of the stresses, the specimens printed in
specimens in the different directions of the coordinate axes are compared. The specimens printed
along the X-axis direction (Figure 14A) or along the Y-axis direction (Figure 14B) have a slight ductile
behaviour with high elongation, good flexural strength, and high rigidity. This reaction is caused by
the filaments being aligned with the main stress direction. The resistance depends on the strength of
the intra-layer bond and the strength of the filaments. The stiffness and flexural strength are slightly
Materials 2019, 12, 3859 15 of 20
higher in the Y-axis orientation specimens. The reason is once again the arrangement of the layers.
Although the two orientations have the filaments parallel to the direction of the stresses, the
specimens printed in the X-axis direction can become delaminated between layers when they are
the X-axis direction can become delaminated between layers when they are bent. The delamination is
bent. The delamination is produced by the breakage of the weak interlayer bonds. The specimen
produced by the breakage of the weak interlayer bonds. The specimen becomes flexible and is unable
becomes flexible and is unable to withstand the bending stress, although the intralayer bonds remain
to withstand
intact. the bending stress, although the intralayer bonds remain intact.

FigureFigure 14. Breaking


14. Breaking section,
section, specimenswith
specimens with orientation
orientation ininthe (A)(A)
the X-,X-,
(B) (B)
Y-, and (C) Z-direction.
Y-, and (C) Z-direction.

In Figure
In Figure 14C,14C,
the the section
section of of therupture
the ruptureof of a
a test
testspecimen
specimen printed in Z-axis
printed orientation
in Z-axis is shown.
orientation is shown.
These specimens have fragile behaviour and little deformation, low resistance
These specimens have fragile behaviour and little deformation, low resistance to bending, to bending, and lowand low
rigidity. This is caused because the layers are oriented perpendicularly to the stresses generated in
rigidity. This is caused because the layers are oriented perpendicularly to the stresses generated in the
the specimen during the bending test. For this reason, failure has occurred in the weak interlayer
specimen during the bending test. For this reason, failure has occurred in the weak interlayer weld
weld without the affection of filament integrity.
without the Theaffection
second of filament
most integrity.
influential factor is the layer height, followed by the filament width. The
The second
smaller mostheight
the layer influential
and thefactor
largeristhe
thefilament
layer height,
width, followed by the
the stiffer and morefilament
resistantwidth. The issmaller
to bending
the layer height
the test and the
specimen. larger
This the filament
is directly related towidth, the stifferofand
the compactness the more
threadsresistant to bending
and the welding is the test
between
threads (Figure 15).
specimen. This is directly related to the compactness of the threads and the welding between threads
(Figure 15). 12, x FOR PEER REVIEW
Materials 2019, 16 of 21

Figure 15. (A)


Figure 15. (A)Test
Testspecimen
specimenwith a layer
with height
a layer of 0.3of
height mm0.3and
mm filament width ofwidth
and filament 0.3 mm.
of Test specimen
0.3 mm. Test
9_2.
specimen 9_2. Microscopic photography. (B) Test specimen with a layer height of 0.1 mm and width
Microscopic photography. (B) Test specimen with a layer height of 0.1 mm and filament of
filament
0.6 mm. Test specimen 21_3. Microscopic photography.
width of 0.6 mm. Test specimen 21_3. Microscopic photography.

Figure
Figure 15A
15A shows
shows thethe extreme
extreme casecase with
with the
the maximum
maximum layer layer height
height of
of 0.3
0.3 mm
mm and
and minimum
minimum
filament
filament width of 0.3 mm. With these dimensions, the threads are cylindrical and produce low
width of 0.3 mm. With these dimensions, the threads are cylindrical and produce low
compaction
compaction and andweakweakwelding
welding owing
owing to to
thethe
scarce contact
scarce surface
contact between
surface threads.
between On the
threads. Onother
the hand,
other
as the layer
hand, as theheight decreases
layer height and theand
decreases filament width increases,
the filament the threads
width increases, have a have
the threads flat shape,
a flat with
shape, a
larger
with a welding surface.
larger welding FigureFigure
surface. 15B shows the optimal
15B shows case with
the optimal case awith
minimum layerlayer
a minimum height of 0.1ofmm
height 0.1
and maximum filament width of 0.6 mm. In summary, the welding
mm and maximum filament width of 0.6 mm. In summary, the welding surface of the threads, surface of the threads, where
where the
micro-welds
the micro-welds are produced between
are produced the chains
between of the polymer
the chains deposited
of the polymer at the beginning
deposited and those
at the beginning andof
the
thosefilament
of the that is then
filament thatdeposited on it, is determinant
is then deposited in the mechanical
on it, is determinant behaviour. behaviour.
in the mechanical The greaterThe the
welding surface, the greater the rigidity and strength of the
greater the welding surface, the greater the rigidity and strength of the piece. piece.
Figure
Figure 1616 shows
shows the the micro
micro scratch
scratch test
test tracks
tracks inin both
both the
the (A)
(A) perpendicular
perpendicular and and (B)
(B) parallel
parallel
direction to the filaments, on the same piece printed in the X-axis direction
direction to the filaments, on the same piece printed in the X-axis direction shown in Figure shown in Figure 14A.14A.
It canIt
be
can be seen how, up to the tested force (70 N), the material deforms ductilely without cracking inbase
seen how, up to the tested force (70 N), the material deforms ductilely without cracking in the the
material, as theas
base material, indenter moves.moves.
the indenter It also It
looks
alsolike
looksthelike
burrs
theproduced by the extruder
burrs produced are torn. are
by the extruder Thetorn.
fact
The fact that there are no disclosures between filaments implies that the adhesion between them in
the same layer is enough to resist the efforts applied during the test.
with a larger welding surface. Figure 15B shows the optimal case with a minimum layer height of 0.1
mm and maximum filament width of 0.6 mm. In summary, the welding surface of the threads, where
the micro-welds are produced between the chains of the polymer deposited at the beginning and
those of the filament that is then deposited on it, is determinant in the mechanical behaviour. The
greater the welding surface, the greater the rigidity and strength of the piece.
Figure 16 shows the micro scratch test tracks in both the (A) perpendicular and (B) parallel
Materials 2019, 12, 3859 16 of 20
direction to the filaments, on the same piece printed in the X-axis direction shown in Figure 14A. It
can be seen how, up to the tested force (70 N), the material deforms ductilely without cracking in the
base material, as the indenter moves. It also looks like the burrs produced by the extruder are torn.
that thereThearefact
nothat
disclosures between filaments implies that the adhesion between them in the same
there are no disclosures between filaments implies that the adhesion between them in
layer is enough to resist the efforts
the same layer is enough to resistapplied during
the efforts the
applied test. the test.
during

Figure 16. Micro


Figure scratch
16. Micro scratchtest: (A)perpendicular
test: (A) perpendicular
to the to the printing
printing direction;
direction; (B) parallel to(B) parallel to the
the printing
printing direction.
direction.

The graph in Figure 17 shows the results of the micro scratch tests: (A) perpendicular and (B)
parallel to the direction of the filaments in the range of test forces. The values of normal force, friction
force, penetration depth, residual depth, and friction coefficient are clearly observed. While the value
of the friction coefficient measured in the perpendicular test shows oscillations, owing to the abrasive
wear of the burrs (see arrows in Figure 17A), in the parallel test, its value remains almost constant. It
could be possible to sense that these pieces are not showing remarkable wear adhesive.
On the other hand, these burrs left during the extrusion process form channels on the piece surface.
If it is true that this worsens the surface roughness of the pieces, they could be useful for retaining
lubricant adhered to the sides of the burr ridges; more taking into account that they do not increase
their friction coefficient too much, as shown in Figure 17.

3.3. Fatigue Test


The parameter that marks the difference between both curves in Figure 18 is the layer height,
being 0.1 mm for the results of this study and 0.3 mm for the referenced study [14].
Materials 2019, 12, 3859 17 of 20

Figure 17. Micro scratch test results: (A) perpendicular to the printing direction; (B) parallel to the
printing direction.

1
Materials2019,
Materials 12,x3859
2019,12, FOR PEER REVIEW 1918ofof21
20

Figure 18. Wöhler curve for the results obtained in this study and those obtained in the work of [14].
Figure 18. Wöhler curve for the results obtained in this study and those obtained in the work of [14].
Although the authors of [14] find that layer height is slightly significant—and although it seems
Although
that the following the authors
assumption of [14] find that
holds: layer height
the higher is slightly
the height layer significant—and
value, the greateralthough it seems
the improvement
that the following
detected regarding assumption
resistance—thisholds:cannot
the higher the height
be assured, layer
as the value,
errors the greater
calculated for the
the improvement
multiplicative
detected
factor and regarding resistance—this
the exponent cannot mean
in both equations be assured, as the
that they canerrors
be thecalculated
same. for the multiplicative
factorTherefore,
and the exponent
althoughina both equations
dependence onmean
the layerthatheight
they can be the same.
is insinuated, the current data do not allow
it toTherefore,
assert it. although a dependence on the layer height is insinuated, the current data do not allow
it to assert it.
4. Conclusions
4. Conclusions
The influence of the layer orientation, layer height, filament width, printing velocity, fill density,
and The
infillinfluence
pattern on of the flexural performance
layer orientation, layer ofheight,
PLA specimens was studied
filament width, printingthrough a Taguchi
velocity, DOE.
fill density,
The following conclusions can be extracted:
and infill pattern on the flexural performance of PLA specimens was studied through a Taguchi DOE.
The following conclusions can be extracted:
1. The orientation of the stacking of the layers is the most influential parameter in the rigidity, in the
1. The orientation of the stacking of the layers is the most influential parameter in the rigidity, in
flexural resistance, and in the maximum deformation.
the flexural resistance, and in the maximum deformation.
2. The layer height and the filament width had a great significance in stiffness and flexural strength
2. The layer height and the filament width had a great significance in stiffness and flexural strength
and no influence on maximum deformation.
and no influence on maximum deformation.
3. Printing velocity had a small, but significant effect on rigidity and flexural strength and no
3. Printing velocity had a small, but significant effect on rigidity and flexural strength and no
influence on maximum deformation.
influence on maximum deformation.
4.
4. The Thefillfill density
density andand infill
infill pattern
pattern had hadnono effectononthe
effect thestudied
studiedmechanical
mechanicalproperties.
properties.
5.5. TheThe orientation
orientation ofof stacking
stacking layers
layers ininY,Y,thethelayer
layerheight
heightofof0.1
0.1mm,
mm,thethefilament
filamentwidth
widthofof0.60.6mm
mm
and the printing velocity of 20 mm/min was the optimal combination
and the printing velocity of 20 mm/min was the optimal combination obtained that will allow obtained that will allow
maximizing
maximizing rigidity
rigidity andand flexural
flexural resistance.
resistance.
6. The printing direction in
6. The printing direction in Y-axis showed theY-axis showed thebest
bestmechanical
mechanicalbehaviour
behaviourowing owingtotoitsitsresistance
resistance
depending
depending ononthethe strong
strong intralayer
intralayer bond.
bond.
7. The large filament width,
7. The large filament width, the small layer the small layerheight,
height,andandthe thelow
lowprinting
printingvelocity
velocityformed
formed testtest
specimens
specimens with
with bettercompaction
better compactionand andbetter
betterwelding
weldingbetween
betweenwires,
wires,and andgenerated
generatedaabetter better
rigidity and resistance
rigidity and resistance to bending. to bending.
8.8. It It could
could not
not bebe ensured
ensured thatthat higher
higher layer
layer height
height improves
improves fatiguelife.
fatigue life.
Materials 2019, 12, 3859 19 of 20

9. Depending on the mechanical property to enhance, the combination of optimal parameters to use
is different.

Author Contributions: Conceptualization, J.A.T.-R. and R.J.-M.; Methodology, R.J.-M., G.G.-G. O.T.-R. And
J.J.R.R.; Software, J.L. And O.T.-R.; Validation, J.L., J.J.R.R. and R.J.-M.; Formal Analysis, G.G.-G. and R.J.-M.;
Investigation, J.A.T.-R., G.G.-G. and O.T.-R.; Resources, J.A.T.-R. and J.L.; Data Curation, J.L. J.J.R.R. and R.J.-M.;
Writing-Original Draft Preparation, J.A.T.-R.; Writing-Review & Editing, J.L., G.G.-G. and R.J.-M.; Visualization, J.L.
And J.J.R.R.; Supervision, J.A.T.-R. And R.J.-M.; Project Administration, J.A.T.-R., Funding Acquisition, J.A.T.-R.,
R.J.-M. and J.L.
Funding: This research did not receive any specific grant from funding agencies in the public, commercial, or
not-for-profit sectors.
Acknowledgments: J.J. Roa would like to acknowledge the Serra Hunter program of the Generalitat de Catalunya.
Conflicts of Interest: The authors declare no conflict of interest.

Abbreviations
AM additive manufacturing
FFF fused filament fabrication
PLA polylactic acid
DOE design of experiments
ANOVA analysis of variance

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