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Abstract
Purpose – This paper aims to explore the effect of bed temperature, primary layer thickness and infill pattern (rectilinear, honeycomb, triangular) on
the mechanical properties of tensile strength and bending strength of 3D printed parts.
Design/methodology/approach – Samples in accordance to various ASTM standards were printed by fused deposition modelling (FDM) method by
varying the various input paramaters such as bed temperature, primary layer thickness and infill pattern (rectilinear, honeycomb, triangular). Tensile
and bending testing was carried out on the printed parts, and post to the testing, fractography has been carried out using scanning electron
microscope.
Findings – With increase in bed temperature tensile strength and flexural strength first increases then decreases. With the increase in primary layer
thickness, tensile strength and flexural strength increase. With regard to infill patterns, triangular and honeycomb exhibit better tensile strength and
better flexural strength.
Practical implications – The 3D printing is increasingly becoming important for manufacturing of engineering parts, determining the process
parameters which could result in better mechanical and physical properties shall certainly help designers and manufacturers globally.
Originality/value – This work elucidates the effect of various process parameters of FDM on tensile and flexural properties of the samples.
Keywords FDM, Additive manufacturing, Tensile strength, Bending strength, Infill pattern, Primary layer thickness
Paper type Research paper
The current issue and full text archive of this journal is available on Received 27 September 2018
Emerald Insight at: www.emeraldinsight.com/1708-5284.htm Revised 20 November 2018
6 December 2018
12 December 2018
World Journal of Engineering
24 December 2018
16/4 (2019) 550–559 11 January 2019
© Emerald Publishing Limited [ISSN 1708-5284] 3 February 2019
[DOI 10.1108/WJE-09-2018-0329] Accepted 20 February 2019
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Fused deposition modelling process parameters World Journal of Engineering
Abhinav Chadha et al. Volume 16 · Number 4 · 2019 · 550–559
dimensional control, better surface finish and close tolerances. compared to model temperature, raster width and colour
Also, greater variety of polymers should be available for use and through experimental design and analysis. Lee et al. (2005)
the mechanical properties of the prototyped parts should be concluded that raster angle, air gap and layer thickness affect
enhanced to maintain their integrity during working (Gajdoš the elastic performance of the compliant FDM ABS prototype.
and Slota, 2013). Christiyan et al. (2016) used ABS 1 hydrous magnesium
The values of process parameters in additive manufacturing silicate composite to test the mechanical properties based on
processes can be more significant as compared to the properties ASTM D638 and ASTM D760 standards for tensile and
of the part material, which is contrary to most of the bending test, respectively. Samples with varying printing speed
manufacturing processes. Parts having same geometry but and layer thickness were made. It was concluded on the basis of
fabricated using different sets of process parameters will have experiments that low layer thickness and low printing speed has
entirely different properties, e.g. strength (Bellini and Güçeri, highest tensile and flexural strength. Vaezi and Chua (2011)
2003; Ahn et al., 2003) or accuracy (G orski et al., 2013). Each explored the effect of binder saturation level, printing layer
combination of process parameters, namely, bed temperature, thickness, binder properties, powder size on the strength and
layer thickness and infill pattern, will produce a different part surface finish of 3D-printed parts. Trdnost and Modelov
structure, ultimately resulting in different values of mechanical (2013) researched the effect of some selected process
properties. parameters on the tensile strength and provided a factor
In a study by Es-Said et al. (2000), the authors demonstrated combination which provided the highest strength. Specimens
the effect of raster orientation along the direction of deposition of ZP 130 powder were prepared with changes in the building
on tensile, flexural and impact strength. Ahn et al. (2002) have orientation, layer thickness and infiltrant. Tymrak et al. (2014)
showed that process parameters such as raster orientation and found elastic modulus and tensile strength for 3D printed parts
air gap considerably effect the tensile strength of the part made from PLA and ABS. The tensile strength for ABS was
55.6 and for PLA was 28.5 and the elastic module is 1806 MPa
Figure 1 Geometrical details of sample for (a) tensile test as per ASTM for ABS and 3367 MPa for PLA. Wu et al. (2015) conducted
D638, (b) flexural test as per ASTM D790 (mm) research on a novel material, polyether-etherketone (PEEK).
They studied the effect of raster angle and layer thickness on
the mechanical properties of 3D printed PEEK parts.
Specimens with layer thicknesses (200, 300 and 400
micrometres) and raster angles (0, 30 and 45 degrees) were
made using a PEEK 3D printing system. The compressive,
tensile and bending strengths were tested, and it was concluded
that PEEK has superior properties than ABS. Sood et al.
(2010) took into consideration five parameters of layer
thickness, orientation, raster angle, raster width and air gap and
studied their effect on tensile, flexural and impact strength of
the test specimen. Lanzotti et al. (2015) have reported ultimate
tensile strength and the nominal strain at break of printed parts
Table I Technical specifications of 3D printer made from (PLA) with 3D printer, by varying the three
Build volume 290 290 500 mm (X,Y,Z) important process parameters: layer thickness, infill orientation
Physical 620 520 965 mm and the number of shell perimeters. G orski et al. (2015)
dimensions performed tensile, flexural and impact strength tests on ABS
Technology Fused deposition modelling (FDM) material samples made with different orientations.
No. of extruders 2 Chac on et al. (2017) studied the effect of layer thickness,
Extruder temp. Upto 300 deg. build orientation and feed rate on the tensile and bending
Print speed 20-300 mm/s (also polymer dependent)
Layer resolution 0.04 to 0.2 mm (for 0,4 nozzle) Table II Variation of process parameters
Print head Swappable nozzles (0.2/0.3/0.4/0.5/0.6 mm)
Parameter Values
Standard nozzle size-0.4 mm supplied with machine
Filament diameter 1.75 mm Primary layer thickness (mm) 0.150 0.175 0.200
Filament materials PLA, ABS, Nylon, Ninja Flex, PETG, Wood, Poly Bed temperature (°C) 40 60 80
Carbonate, PLA/PHA, PCTPE, T-glass Infill pattern Grid Triangular Honeycomb
Support filament HIPS
XYZ Accuracy 12.5, 12.5, 5 microns
Build plate MK2A heat bed with borosilicate glass plate
Build plate temp. 50-100 deg. Table III Process parameters for sample preparation
Supported OS Windows Infill percentage 50%
Power supply Input 120/240 V AC Flowrate 100%
Output 24 V DC 20 A X-Y displacement speed (mm/min) 3600
Operating ambient 15 to 35 degree Z displacement speed (mm/min) 1000
temp. Printing temperature (Extruder) 220°C
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Fused deposition modelling process parameters World Journal of Engineering
Abhinav Chadha et al. Volume 16 · Number 4 · 2019 · 550–559
strength of PLA samples. Decrease in ductility was observed angle, raster width and layer height on tensile strength in
with increase in layer thickness and feed rate. Benwood et al. another study (Rajpurohit and Dave, 2018b).
(2018) investigated the effects of bed temperature, melt Istif et al. (2017) conducted tensile test on PLA specimens
temperature and raster angle on PLA-fabricated specimens. fabricated with different orientations and noted average tensile
Thermomechanical analysis (differential scanning calorimetry, strength and elastic modulus. The specimens were also
dynamic mechanical analysis, heat deflection temperature) was subjected to cyclic loading to determine material’s deformation
thereafter conducted on these specimens. Li et al. (2018) mechanism. From experiments, it was concluded that the
provided a quantitative relationship between the parameters of material showed viscoplastic behaviour. Abbas et al. (2018)
layer thickness, deposition velocity and infill rate and tensile evaluated tensile, compressive and bending strength for PLA
strength of the PLA part. It was concluded that tensile strength samples by varying layer thickness, infill density and print
is affected by interface bonding state, which is determined by orientation by using Taguchi method. An increase in strength
heat transition. Rodriguez-Panes et al. (2018) did a was observed with increase in layer thickness and infill density,
comparative study on the tensile strength of the parts produced while 45° print orientation provided greater strength than at 0°
by ABS and PLA. The parameters varied were layer height, and 90°. Reducing the infill percentage value considerably
infill density and layer orientation. The output variables were decreased the printing time.
chosen as tensile strength, tensile yield stress, modulus of Chari et al. (2018) varied infill, resolution, temperature of
elasticity and nominal strain at break. Tontowi et al. (2017) PLA samples and investigated changes in compression
examined the response of process parameters on tensile strength, hardness with respect to these parameters. Taguchi’s
strength and dimensional accuracy of PLA parts. Layer L9 orthogonal array was used to find the number of
thickness, melt temperatures and raster angles were varied, and experimental models. Choudhary (2018) studied the effect of
optimization of these variables was done using Taguchi and layer thickness, pitch and raster angle on tensile strength and
response surface methods. Rajpurohit and Dave (2018a) hardness of PLA parts. The maximum tensile strength was
investigated the effect of raster angle on tensile strength of PLA achieved as 52.6 MPa at layer thickness (0.5 mm), pitch
specimen. The angles were varied from 0° to 90°. Parts with (4 mm) and raster angle (0°), while maximum hardness of 82
criss-cross raster angles were also fabricated and compared with HV was achieved at layer thickness (0.4 mm), pitch (5 mm) and
parts made with unidirectional raster angle. 0° raster angle raster angle (0°). Lužanin et al. (2014) discussed the effect of
showed maximum tensile strength, while 90° showed infill, layer thickness and deposition angle on the flexural
minimum. The authors further included the effect of raster strength of PLA specimens. The authors reported that the
552
Fused deposition modelling process parameters World Journal of Engineering
Abhinav Chadha et al. Volume 16 · Number 4 · 2019 · 550–559
effect of layer thickness was the most dominant, and interaction Figure 2 (a) 3D printed samples for tensile test (ASTM D638), (b) 3D
between infill and deposition angle was also significant. In a printed samples for flexural test (ASTM D790)
similar study carried out by Fernandez-Vicente et al. (2016)
who studied the effect of infill pattern and infill density on the
tensile strength of ABS specimens. The authors reported that
infill pattern had a minor effect on the tensile properties of the
specimen while infill density had a greater impact.
Ebel and Sinnemann (2014) fabricated PLA and ABS
samples by varying infill amount and pattern. It was concluded
that PLA samples had higher tensile strength compared to their
ABS counterparts. Also completely filled samples possessed
higher strength than partially filled samples.
PLA material is used extensively for a variety of automotive
and industrial applications in general and for MEMS, Robotic
applications and medical applications in particular (Yazdi et al.,
2016; Abdallah et al., 2017; Haleem et al., 2018; Chae et al.,
2015). As additive manufacturing is increasingly becoming
important for manufacturing of these parts, determining the
process parameters which could yield better mechanical and
physical properties shall certainly help designers and
manufacturers globally. This paper studies the effect bed
temperature, primary layer thickness and infill pattern
(rectilinear, honeycomb, triangular) on tensile strength and
bending strength of the 3D printed part.
3. Results and discussions almost linear relation with primary layer thickness. The results
3.1 Tensile strength are in conformance to studies carried out by Benwood et al.
3.1.1 Effect of primary layer thickness on tensile strength (2018)
Figure 3 shows that there is an increase in tensile strength with Figure 4 shows that there is an increase in tensile strength
increase in primary layer thickness for all infill patterns. The with increase in bed temperature for honeycomb infill pattern
bed temperature is kept constant at 40°C. For triangular infill and the relation is almost linear. The primary layer thickness is
pattern the change in strength is more prominent compared to kept constant at 0.2 mm. For triangular infill pattern, the
honeycomb and grid pattern. Honeycomb structure shows an tensile strength decreases with increase in bed temperature. For
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Fused deposition modelling process parameters World Journal of Engineering
Abhinav Chadha et al. Volume 16 · Number 4 · 2019 · 550–559
grid pattern, the strength first increases then decreases with Figure 6 Variation of flexural strength with primary layer thickness
maximum strength in the range between 55°C and 60°C.
Keeping bed temperature and primary layer thickness Flexural strength (grid)
Flexural strength (Triangular)
constant at 40°C and 0.2 mm, respectively, effect of infill Flexural strength (Honey comb)
pattern is studied and represented in Figure 5. Triangular infill 52
pattern shows maximum tensile strength, whereas honeycomb
50
shows lowest.
26.5
3.3 Break strain
26.0 The effect of primary layer thickness shows varying trends as
25.5 shown in Figure 9 for all the three patterns. The bed
25.0
24.5
temperature is kept constant at 40°C. For honeycomb pattern,
24.0 break strain first decreases and then increases, whereas for
23.5 triangular and grid structures, break strain increases with the
23.0
22.5
increase in primary layer thickness. Grid pattern shows an
22.0 almost linear relation, and triangular pattern possesses more
21.5 break strain compared to grid.
21.0
The effect of bed temperature shows varying trends as shown
40 50 60 70 80
in Figure 10 for all the three patterns. The primary layer
Bed temperature (celsius)
Figure 5 Variation of tensile strength with infill pattern Flexural strength (grid)
Flexural strength(Triangular)
66 Flexural strength (Honey comb)
64
62
60
Flexural strength (Mpa)
58
56
54
52
50
48
46
44
42
40
38
40 50 60 70 80
Bed temperature (celsius)
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8.5
8.0 honeycomb (Figures 14 and 15).
7.5 After performing Scanning Electron Microscope (SEM) test
7.0 on the samples, it was found that grid structure showed brittle
6.5
failure. This could be seen from the SEM images where the
6.0
layers did not show much deformation in the fracture zone.
Honeycomb structure on the other hand showed ductile
5.5
fracture. The SEM images showed considerable deformation in
5.0
the fracture zone. Triangular pattern (Figure 15) fracture was
4.5
0.15 0.16 0.17 0.18 0.19 0.20
intermediate between ductile and brittle as showed by the SEM
Primary layer thickness (mm) images.
3.5 Discussions
The results show that the tensile strength for triangular pattern
Figure 10 Variation of break strain with bed temperature is maximum, whereas for honeycomb pattern it is minimum.
The infill density of all the three patterns was kept constant at
Break strain (grid)
Break strain(traingular)
11.0
Break strain (Honeycomb) Figure 11 Variation of break strain with infill pattern
10.5
10.0
9.5
9.0
8.5
Break strain (%)
8.0
7.5
7.0
6.5
6.0
5.5
5.0
4.5
4.0
3.5
40 50 60 70 80
Bed temperature (celsius)
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Figure 12 Representative SEM image corresponding to grid pattern Figure 15 Representative SEM image corresponding to triangular
after tensile test pattern after flexural test
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Abhinav Chadha et al. Volume 16 · Number 4 · 2019 · 550–559
Figure 17 Variation of strength to weight ratio with different infill With increase in bed temperature, flexural strength first
patterns increases then exhibited a decreasing trend. The
maximum change is about 12.01 per cent with layer
thickness 0.2 mm and triangular infill pattern.
With increase in primary layer thickness, flexural strength
increases. The change is about 9.456 per cent with bed
temperature 40°C and honeycomb infill pattern.
Out of the three infill patterns, triangular and honeycomb
exhibit better flexural strength. The maximum difference
being 11.42 per cent with bed temperature 40°C and
primary layer thickness at 0.2 mm, but triangular pattern
exhibited maximum weight at same infill percent.
The results shall be helpful for designers and
manufacturers for selecting process parameters for better
mechanical strength of 3D printed parts.
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