Vol 11, Issue 11,NOV / 2020

ISSN NO: 0377-9254

Impact of process parameters on part properties and
materials used in FDM: A Review
Prashant Singh1, Nitesh Kumar Dixit 2
1
M.Tech Student, 2Assistant Professor
Mechanical Engineering Department,
Institute of Engineering &Technology, Dr. R. M. L. Avadh University, Ayodhya,
Email- prashantsp143@gmail.com
Abstract: material as follows: Layer thickness, infill density,
FDM is a material extrusion AM process that serves raster angle, building orientation, raster gaps,
the purpose of fabrication of parts of very complex environment temperature, extrusion temperature etc
shapes at low processing time. Mechanical . All of these parameters affect the mechanical
characteristics of FDM parts are strongly dependent properties of FDM parts. Researchers concentrate
on process parameters selected during fabrication. on those key parameters that can be seen in the
The research work is carried out for understanding result and discussion. FDM parts are used in
the materials which are used in the FDM. In order medical components, space application automotive
to explain materials, process parameters and their bumper and dashboard wheel [7-15]. The aim of this
effect on mechanical properties, the paper discusses review is for recent and significant field research
the research work done. The outcome reveals that and getting the answers of following questions?
the polymer that is most often used is ABS and What are the materials used in FDM? What are the
PLA, other materials are- PA, PC, PEI, PEEK and process parameters that influence mechanical
Zortrax. The mechanical properties and component properties? and how?
accuracy are greatly influenced by process Literature Review-:
parameters (infill density, layer thickness, building According to reviewed papers, this section will discuss
orientation, raster gaps, raster angle, environment on two point:-
temperature, extrusion temperature, etc). 1. Raw material used.
Keywords: FDM, ABS, PLA, Mechanical properties, 2. Process parameter
Accuracy, Parameter. of FDM and its influence
Introduction: on mechanical properties
Fused deposition modeling (FDM), also known as and accuracy. Raw
fused filament fabrication (FFF), a material Material used:
extrusion additive manufacturing process[1], is fast From the reviewed papers, there are different types
growing technology having the ability of building of polymers used in FDM which are categorized as
the complex geometrical shapes functional parts in follows:- ABS (Table1) [7-20], PLA (Table2) [21-
reasonable build time. In the modern competitive 30], PEI, PEEK, PC (Table 3) [31-36], Studies
market, every industry tries to reduce product focused on PA , Zortrax proprietary materials
development cycle, hence they shift their focus to shown (Table 4) [37-39].
rapid fabrication techniques from traditional This categorization aims to give information to
methods [2-5]. Easy operation, high material users and researchers when they need information
utilization, high automation and flexibility are the about FDM raw material, influence of process
main advantages of FDM [6]. A wide range of parameters or mechanical properties. We can see
thermoplastic materials can be used and can be that ABS [21-30] and PLA [21-30] are the most
combined with ceramic or metallic powder. ABS commonly used polymers in FDM. ABS parts being
and PLA are the most widely used filament material anisotropic and brittle in nature [8] have good
in FDM. Some others are- PEI, PEEK, capability in high stress under quasi static and
polycarbonate (PC), polyamide(PA) and zortrax. dynamic load and proved ABS made FDM to be
There are some parameters of the FDM process effective in dynamic loading [10].PLA is listed
which influence the mechanical properties of the

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separately as it is more printable and has higher
mechanical properties than other plastics except
some type of PC, nylon and composite blends
[25].PEI and PEEK are also categorized separately
as PEEK is high performance polymer best suited
for space application having semicrystalline in
nature [32]. Zhaobing Liu et.al investigated the
mechanical properties of wood, ceramic,
Table 1: Studies focused on ABS.
STUDY TITLE/ RESEARCH
OBJECTIVE
A. K.Sood Parametric appraisal of
(2009)[7] fused modelling process
using the grey taguchi
method
A. K.Sood , S. S. Experimental investigation
Mahapatra and empirical modelling of
(2011)[8] FDM processed part for
compressive strength
improvement
Ranjeet Kumar A study on dimensional
Sahu, A.K. Sood accuracy of fused
(2013)[9] deposited modelling (FDM)
processed part using fuzzy
logic
Hesamodin Jami Dynamic response of FDM
(2013) [10] made ABS parts in
different part orientation
Gorsky ( 2014)[11] Building orientation
influence of impact
strength experimental
investigation
Farzad Rayegani & FDM process prediction
Godfrey C. and optimization using
Onwubolu group method for data
(2014)[12] handling (GMDH) and
differential evolution
Gorski, 2015[13] Building orientation effect
on tensile strength
experimental study
Ziemian intechopen Anisotropic mechanical
(2015)[14] properties: Tensile and
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Vol 11, Issue 11,NOV / 2020
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aluminium,copper and carbon fiber based on PLA
and
concluded that these composites have similar or
even increased mechanical properties than virgin
PLA made parts [28] while Sibi compared PA12
with PLA using tensile test and found much more
stronger than PLA with very good lubrication
properties [39].
MATERIAL VARIABLE MECHANICAL
PARAMETER PROPERTIES/
ACCURACY
ABS layer thickness, build Dimensional accuracy
orientation, raster
angle, air gap, raster
width
ABS Layer thickness, build Compressive stress
orientation, raster
angle, air gap, raster
width
ABS Layer thickness, build Dimensional accuracy
orientation, raster
angle, air gap, raster
width
ABS Build orientation Dynamic and static
stress Strain
ABS 5 building orientations Impact strength
on x and y axes
ABS Air gap, raster width, Tensile strength
orientation, raster
angle
ABS 2 orientation along x Tensile strength
axis (0, 90), Y axis
orientations (0- 30, 5°
increments)
ABS 4 raster orientations, Tensile compressive,
defined machine flexural impact and
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fatigue behavior default values for fatigue strength
parameters

P.J. Nunez Dimensional and surface ABS Density, layer Tensile strength,
(2015)[15] texture characterization in thickness flexural strength, tensile
FDM with ABS plus modulus

Ksawery Mechanical properties of ABS & Density, layer Tensile strength, elastic
Szykiedans FDM and SLA low-cost 3- PLA thickness modulus
(2016)[16] D printer

M. Dawoud (2016) Mechanical behavior of ABS Air gap, raster gap, Tensile strength,
[17] ABS raster angle flexural strength, tensile
modulus

N. Mohammad Effect of FDM process ABS Layer height, infill Tensile strength,
Raffic (2017)[18] parameter in ABS plastic density, raster angle, flexural strength, tensile
material raster width, air gap modulus

Adrian Rodriguez- Influence of parameter on ABS & Layer height, infill, Tensile yield stress,
Panes (2018)[19] mechanical behavior of PLA orientation along x- modulus of elasticity,
ABS and PLA axis, y-axis tensile strength

M. Samykano Influence of printing ABS Layer height, infill Tensile strength, elastic
(2019)[20] parameter on ABS density, raster angle modulus, yield strength,
fracture strength,
toughness

Table 2: Studies focused on PLA.

MF Afrose Effect of part build PLA Orientation along x- Tensile strength,

(2015)[21] orientations on fatigue axis, y-axis elastic modulus
behaviour of FDM- processed
material

J.M. Chacon Additive manufacturing of PLA Layer thickness, feed Ultimate tensile
(2017)[22] PLA structures using FDM rate, build orientation strength, flexural
Additive strength

Vladimir E. Strength of PLA additives PLA Layer thickness, nozzle Ultimate tensile
Kuznetsov (2018) fabricated with FDM the use diameter strength, flexural
[23] of 3-d printer as a function of strength
geometrical parameters of the
process

Radoslaw A. Mechanical properties PLA Temperature, annealing flexural stress, strain

Wach enhancement of FDM-PLA time
(2018)[24] part using thermal annealing

Ana Pilar Valerga Influence of PLA filament PLA Different material Tensile strength ,
(2018)[25] conditions on FDM parts roughness

Shilpesh R. Effect of process parameter PLA Raster angle , raster Tensile strength
Rajpurohit on tensile strength of FDM width, layer thickness
(2018)[26] printed PLA part

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Jose C. Camargo Mechanical properties of the PLA Infill Density, layer Tensile strength ,
(2019)[27] PLA-graphene part . thickness roughness

Zhaobing liu Mechanical characteristics PLA Raster angle, Tensile strength,

(2019) wood , ceramic, metal and orientation elasticity modulus
[28] carbon fiber based PLA
composites using FDM

Joao Fernandes Study of the influence of 3d
(2019) [29] printer parameters on the
mechanical properties of PLA
PLA Raster angle , layer Ultimate Tensile
thickness, infill density, Strength, Yield
extrusion temperature Strength, Modulus of
Elasticity and
Elongation at Break

Mohammad S. Influence of nozzle PLA Nozzle temperature WD, DA, density

Alsoufi (2019) temperature in FDM 3D
[30] printed pure PLA and PLA+

Table 3: Studies focused on PEI and PEEK, PC .

Shouling Ding Influence of nozzle
(2019) [31] temperature and orientation
on mechanical properties
PEI & Nozzle temperature, Relative density,
PEEK building orientation flexural
strength, tensile
strength ,
break elongation.

M Rinaldi (2018) Additive layer manufacturing PEEK Infill density, axis Stress , strain
[32] of PEEK via FDM of printing

Rama Srikar Effect of FDM process PEEK Layer thickness, Tensile strength,
Mutyala parameters on the mechanical printing speed , compressive strength
(2019)[33] properties of CFR-PEEK orientation

Ignazio Blanco Thermal behaviour of PEI 5 & 10% of PETG Viscosity,

(2018)[34] PEI/PETG blends for the processability
application in fused
deposition modeling (FDM)

J. M. Puigoriol Flexural fatigue properties of PC Raster angle , build

Forcada polycarbonate Fused orientation Stress strain curve
(2018)[35] deposition Modelling
specimens

Sherri L. messimer Characterization and PC Raster angle , build Thermal behavior,

(2018) [36] processing behaviour of orientation adhesion
heated Al-PC composites
build plates

Table 4: Studies focused on PA , Zortrax proprietary materials.

David Ian Advances in 3D Printing & PA12 Layer thickness, fill Tensile strength
Wimpenny Additive Manufacturing scan spacing, and
(2017)[37] Technologies orientation

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Xia Gao Fused deposition modeling
(2019)[38] with polyamide 1012
S. Sibi Enhance the material
Chakaravarthi properties FDM filament
(2018)[39] using PA12
Ales Mizera Tensile impact behaviour of
(2018)[40] 3D
printed parts on FFF/FDM
printer Zortrax M200
Process Parameter of FDM:-
Samykano et. al [19] studied the major process
parameter and its influence on mechanical
properties for ABS specimens, the same by
Ignazio Blanco et. al for PEI [34] and by João
Fernandes et. al for PLA[28] followed by
Chacon et. al [21], by Rama Srikar Mutayala
et. al for CFR-PEEK[33].
From the reviewed papers, it can be seen that
there are various process parameters which
influence the mechanical properties and
accuracy. These properties can be listed as:-
1. Raster angle:- direction of beads of material
relative to the loading part.
2. Building orientation:-how the part should be
positioned when used.
3. Layer thickness:- height of deposit slice from fdm
nozzle.
4. Infill density:- the amount of filament printed
inside the parts.
5. Raster gap:- space between two beads of material.
6. Air gap:- space between beads of deposited FDM
material.
7. Raster width:- width of the deposition path
relative to tip size.
8. Extrusion temperature
Raster angle is one of the most important
parameters impacting mechanical behavior which
influences the anisotropy of FDM parts. Increase in
raster angle improves tensile strength [12]. Dawoud
noted that −45◦/+45◦ raster angle layup offers
maximum tensile and impact strength and in case of
flexural strength, 0/90◦ scaffolding system offers
maximum for ABS specimen [17] while Shilpesh
et. al conclude that for PLA specimen, 0◦ raster
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Vol 11, Issue 11,NOV / 2020
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PA1012 Nozzle temperature, Tensile strength
bed temperature,
raster angle.
PA12 Comparison Tensile strength,
between PA12 and charpy
PLA impact test.
Zortrax m2000 Layer thickness Tensile strength.
angle had maximum tensile strength[26]. In
another study, Zhaobing Liu et. al found that PLA
composites samples printed in on-edge orientation
with +45◦/-45◦ raster angle had highest mechanical
strength and modulus[28]. Building orientation is
also an important parameter that affects the
mechanical properties. Chacon et. al noted that
upright orientation of PLA specimens had brittle
fracture behavior and on-edge & flat orientation
showed ductile fracture behavior[22]. Forcada et.
al preferred XY & YZ build direction and kept
machine transverse path for higher life[35] where
Rayegani concluded that 0◦ orientation had
maximum tensile strength for ABS specimen[12].
In another study, Afrose et. al concluded that 45◦
orientation have higher fatigue life and toughness,
absorbs more energy than X & Y- orientation for
PLA[21]. A study by Chacon et. al reported that
tensile and flexural strength increases and ductility
decreases with increases in layer thickness and also
by camargo [22,27]. In a comparative study by
Panes et. al, layer height effect was more in PLA
than ABS as it reduced tensile strength by 11% in
PLA and by 8% in ABS [19]. Ales Mizera et. al
concluded that impact strength and impact force
decreases with increase in layer thickness for ABS
& HIPS specimen, hence finally concluded that for
impact application lower print layers were suitable
depending upon time and economic demand[39].
Studies showed that mechanical properties improve
with increase in infill[18][27]. Raffic et. al noted
that model building time, cost and part strength
increases with increases in infill density[18]. Some
studies concluded a negative raster gap as the most
significant factor in enhancing mechanical
properties [12][17][18]. Shilpesh et. al suggested
that higher value of raster width improves tensile
strength to a certain extent[26]. Adrian Rodriguez-
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panes did a comparative study of tensile mechanical
behaviour of ABS and PLA using FDM and gave
the result that ABS showed more variability than
PLA by varying parameters.(infill percentage,
layer thickness and build orientation)[19].
Szykiedans et. al conducted tests for tensile
strength and elastic modulus of printed ABS
components produced with the application of FDM
and SLA (Stereolithography technology)[15]. Ai
Qing pan et. al found that with increase in nozzle
moving rate, slice thickness adhesive strength
increases, also concluded that slice thickness has
more influence to adhesive strength than nozzle
rate[6]. Joao et. al studied the effect of parameter by
conducting tensile test(using UTM instron3369)
and water absorption test (using ASTM D570-98)
with coated and uncoated specimen of PLA and also
noted that raster angle and temperature became less
relevant at higher infill and polyurethane protective
material was best from water absorption test[29].
Shouling Ding et. al investigated the relationship of
nozzle temperature, building orientation and
material properties analyzing morphology,
chemical composition and SEM, and also
concluded that PEEK possessed higher toughness
than PEI [31]. Ignazio blanco concluded that the
PETG in blend lowered the resistance to thermal
degradation as a function of weight by TGA
analysis using PEI/PETG blend [34]. Messimer et.
al noted Al-PC composites built plates as a feasible
alternative to traditional glass and aluminum one
[36]. Nunez et. al experimented to determine the
dimensional accuracy on surface characteristic with
two densities (low & solid) and layer thickness
(0.178 mm, 0.254 mm) and found best dimensional
behavior with maximum layer thickness(0.254) and
solid density(100%), also best surface finish with
less layer thickness (0.178mm) & solid
density(100%)[15]. A.K. Sood et. al conducted a
experiment using grey taguchi method to improve
the performance characteristic and result showed
that a layer thickness of 0.254 mm, part orientation
of 0◦, raster angle 0◦, raster width 0.4564 mm and
air gap 0.008 mm will optimize the performance
characteristics[7]. In another study, Ranjeet Kumar
Sahu et. al studied the application of fuzzy logic
reasoning using taguchi method for improvement of
dimensional accuracy and concluded that the
optimum level of optimal process parameter were:
layer thickness 0.178, orientation of 0◦, raster angle
of 0◦, raster width 0.4564 and air gap 0.008[9]. Due
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Vol 11, Issue 11,NOV / 2020
ISSN NO: 0377-9254
to technological evolution of 3-D printers, the
research work focused on the fabrication of parts
from a 3D open source printer for dimensional
accuracy investigation. Therefore, authors
investigate the relationship between the 3D open
source printer process parameters along with their
interactions and the dimensional accuracy of the
product in different directions of built parts using
the Taguchi parameter design method. Further,
grey relational method can effectively be
implemented to get the single optimum factor level
[42-43].
Conclusion:
This review aims to study the polymer used in FDM
and process parameters and its effect on mechanical
properties. From the all studied papers, it can be
concluded that:
1. In FDM a wide variety of thermoplastic
can be used such as ABS ,PLA , PEEK,
PEI, PC, PA and ZORTRAX
MATERIAL. Wood, ceramic, aluminium,
carbon fiber composites can also be used.
2. There are various parameters that
influence the mechanical properties : layer
thickness, raster angle, raster width, build
orientation, air gap, infill density etc.
3. Increase in raster angle,
layer thickness and infill
density improves
mechanical properties. 4.
A negative raster gap
enhances the mechanical
properties.
5. FDM parts can be used in medical, space
applications,dashboard wheel etc.
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