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Effect of Infill Pattern and Ratio On The Flexural and Vibration Damping Characteristics of FDM Printed PLA Specimens
Effect of Infill Pattern and Ratio On The Flexural and Vibration Damping Characteristics of FDM Printed PLA Specimens
Effect of infill pattern and ratio on the flexural and vibration damping
characteristics of FDM printed PLA specimens
Mustafa Özgür Öteyaka a, Fatih Hayati Çakir a, *, Mehmet Alper Sofuoğlu b
a
Eskişehir Vocational School, Eskisehir Osmangazi University, Eskişehir, Turkey
b
Department of Mechanical Engineering, Eskisehir Osmangazi University, Eskisehir 26480, Turkey
A R T I C L E I N F O A B S T R A C T
Keywords: 3D printing technology has started to be used in many different areas of our lives. In this study, the panels’
3D Printing flexural behaviors and vibration-damping capabilities produced in different infill patterns (Grid, Cross, and Tri-
Flexural strength hexagon) and different infill ratios (0 %, 20 %, 40 %, 60 %, 80 %, and 100 %) were investigated. The specimen
Fused deposition modeling
dimensions were 12.7 mm in width, 127 mm in length, and 3.2 mm in thickness. A biopolymer polylactic acid
Modal analysis
Vibration damping
(PLA) filament with Ø 1.75 mm was used to produce test specimens. Fused Deposition Modeling is a modern
additive manufacturing technique; however, optimization is needed to enhance the properties of 3D-printed
parts. The flexural properties, as well as vibration-damping characteristics of the 3D-printed specimen, were
evaluated experimentally. The results show that the infill pattern and ratio significantly affect flexural behavior
and vibration-damping properties. The flexural tests showed that the highest flexural strength was obtained in
the Tri-hexagon pattern, while the highest damping capability was obtained on Cross pattern specimens.
Additionally, with the increasing infill ratio, the flexural modulus, and flexural strength increase. The specific
strength value obtained for the 20 % fill rate for all patterns was observed as maximum Best damping properties
were obtained on a 40 % infill ratio with all the different tested patterns. This study also showed that infill
pattern and ratio design could improve the plastic parts’ properties, and 3D printing provides an easy way to test
the properties of different infill patterns and ratios.
* Corresponding author.
E-mail address: fcakir@ogu.edu.tr (F.H. Çakir).
https://doi.org/10.1016/j.mtcomm.2022.104912
Received 14 September 2022; Received in revised form 4 November 2022; Accepted 9 November 2022
Available online 12 November 2022
2352-4928/© 2022 Elsevier Ltd. All rights reserved.
M.Ö. Öteyaka et al. Materials Today Communications 33 (2022) 104912
feedstock [6–8]. The part’s manufacturing starts with molting material 2. Materials and methods
above the glass transition temperature and then extruded through the
nozzle. However, many parameters influence the quality as well as the The present study investigated the effect of different infill patterns
mechanical properties of FDM parts. Infill ratio, printing speed, bed and ratios on mechanical and vibrational properties. In order to effi
temperature, nozzle temperature, raster angle, and infill pattern are ciently generate different patterns and infill ratios, the FDM method was
some of the basic parameters that affect the quality of the FDM process. chosen to manufacture the test specimens from PLA filaments. The
It was demonstrated by Öteyaka et al.[6] that both feedstock material, specimen dimensions were determined per standard bending test spec
infill pattern, and infill ratio play a significant role in determining the imen per ASTM D638 standard. At least 3 specimens were produced
strength of the parts. Moreover, they revealed that the addition of car under each condition and tested to obtain reliable results.
bon fiber reinforcement in the PLA reduces the ultimate tensile strength
against PLA. The importance of infill patterns were also notified by other 2.1. 3D printing process
researchers, Akhoundi et al. [9] showed that concentric patterns had
better mechanical properties over rectilinear, honeycomb, and Hilbert The specimens were produced with the fused deposition modeling
curve structures. Dobos et al. tested the flexural and tensile properties of (FDM) techniques. A gray-color polylactic acid Biopolymer (PLA) 1.75
different infill patterns (Honeycomb, Concentric, Hilbert Curve, Recti mm diameter was used to print the test specimens. The filament model
linear) and different infill ratios (40 %, 60 %, 80 %, and 100 %). The used was Zaxe PLA. The used printer model was ZAXE X1 PLUS, a 3D
authors stated that the optimum infill ratio for obtaining maximum FDM printer that has a heated table with dimensions of (X) x (Y) 300 mm
specific strength is 40 % regardless of infill ratio. It was also stated that x (Z) 300 mm and was used to manufacture specimens. The FDM pa
the a correctly developed Finite Element Method can be integrated to rameters used in the manufacturing of specimens are given in Table 1.
optimum pattern design to lower the number of experimental tests [10]. These parameters kept the same to produce specimens with different
Obtaining optimum vibrational characteristics by adding support patterns and infill ratios. The specimen manufacturing begins with
structures is an aspect and, generally, an overlooked potential of the drawing the specimens with CAD software. In this study, Solidworks
additive manufacturing method, which gives the possibility of designing software was used to generate the models of tested patterns. The di
parts with tailored modal parameters. The natural frequency, damping mensions of the specimens (Fig. 1) were determined according to the
ratio, or stiffness of a specific part can be adjusted with the design pa ASTM D638 standard. The patterns were created in CAD software the
rameters of additively manufactured parts. Additive manufacturing PRT file was transformed into an STL file. The XDesktop V2.1.8 software
methods make it easier to test different support structures, such as was used to slice the model to prepare for printing. Three different
trusses, on the mechanical behavior of parts. 3D truss lattices have patterns, Cross pattern (Fig. 2), Grid pattern (Fig. 3), and Tri-Hexagone
relatively high stiffness and yield strength at low density. They play a (Fig. 4) pattern, were selected to produce the specimens. In addition, 6
crucial role in lowering the overall weight of structures and have been groups of specimens were produced with different infill ratios (0 %, 20
tested and optimized in a variety of applications. A lightweight 3D truss %, 40 %, 60 %, 80 %, and 100 %) for each pattern. These figures show
lattice structure usually has low damping, causing early mechanical the shape of infill designs; the red lines show the idle moves of the
damage from resonant vibrations. When it comes to achieving both nozzle. The produced specimens were first tested in modal analysis tests,
structural and vibrational requirements, an excellent combination of and then bending tests were performed.
stiffness and damping can be achieved by selecting the right materials After the production of specimens, the weight of all specimens was
and configurations [11–16]. Several studies have been conducted to measured with a precision scale, and the average weight of specimens
understand and quantify different aspects of acoustic and vibrational was presented in Table 2. For this purpose, a precision scale (SHIMADZU
damping [17–26]. The method of constrained layer damping (CLD) was AY 220) with a sensitivity of 0.1 mg was used. The repeatability of the
studied, and it is the most popular method of vibration suppression [19]. scale was 0.05 mg. The scale was calibrated before the measurements.
Many optimization techniques have been successfully applied to opti The 0 % infill ratio represents the hollow prism with wall thickness. As
mize the location and dimensions of CLD in order to maximize structural the infill ratio increases, the support patterns form and get denser with
damping while minimizing additional mass [20–23]. Similarly, filling an increased infill ratio. The 100 % represents a fully filled sample with
the core voids with foam or viscoelastic material has also been studied as the following different patterns.
a way to balance the structural and vibrational performance of the lat
tice truss [24,25]. More papers have been published on vibration 2.2. Flexural strength tests
damping optimization with honeycomb cores in order to reduce struc
tural damping loss factors [19,22]. Most 3D-printed polymers have Since the mechanical design approach mostly counts on the prop
inconsistent material properties, particularly those related to damping. erties of used materials, mechanical tests play a vital role in determining
It is therefore necessary to investigate the effectiveness of 3D-printed the capabilities of a produced part. In the present study, a flexural test
structures further. was chosen to determine the mechanical behaviors of produced speci
In addition to the strength properties of a material, the response of mens. A three-point bending configuration was used. Bending is a
the material to vibration is an important aspect. Vibration is a significant unique form of loading, which includes both compression and tension of
problem that needs to be controlled in machine systems. In order to cope test specimens. In bending, the upper fibers are exposed to compression
with this problem, special vibration-damping elements can be used, and stresses, while the lower fibers are exposed to tensile stresses. Generally,
it is desirable that the elements in the structure contribute to the
damping to a certain extent. In this study, 3D-printed materials with 4
Table 1
different patterns and 5 different infill rates were produced. The weights FDM parameters for manufacturing bedding specimens.
and volumes of these materials were measured, and then their vibration-
Parameter Magnitude
damping abilities were analyzed with the impulse hammer test. Finally,
the mechanical properties of the produced specimens were tested by Nozzle diameter 0.4 mm
bending test. Although there are studies in the literature on the effects of Layer thickness 0.15 mm
Table temperature 55 ◦ C
different patterns and infill ratio values on the strength of 3D-printed Nozzle temperature 205 ◦ C
parts, there are not enough studies on the effects of process parame Build orientation Flat
ters on the vibrational damping properties. Top and bottom solid layer 4
Perimeter count 3
Printing Speed 60 mm/s
2
M.Ö. Öteyaka et al. Materials Today Communications 33 (2022) 104912
the initial crack forms in the tension zone that lower the flexural tensile imen size, so the span length (L) was set as 51.2 mm. The loading speed
strength, and based on the test specimen structure, it either fails or bends (R) was calculated per Eq. (I). The (Z) was a constant (0.01 min− 1); after
as two sides become parallel. calculation, the loading speed was set as 1.36 mm/min. A specimen
In the present study, Shimadzu AG-IS 250 kN universal testing ma image of the bending test is presented in Fig. 5. The flexural stresses
chine was used to conduct three-point bending tests. The universal were calculated per Eq. (II); (F) is the test load, and (w) is the width of
testing machine can be adjusted to conduct tensile, compression, the test specimen. The flexural modulus was calculated per Eq. (III).
bending, or fatigue tests. The bending tests were conducted per ASTM
ZL2
D790 standard. The radii of the loading nose were 5.0 mm. According to R= (I)
6d
ASTM D790, the L is the length of the span, the (d) is the specimen
thickness, and (R) is the loading speed. ASTM D790 suggests a span 3FL
length according to specimen thickness (d). The suggested bending = σ (II)
2wd2
specimen sizes are 127 mm in length, 12.7 mm in width with 3.2 mm in
thickness. The recommended span length is equal to 16 times of spec
3
M.Ö. Öteyaka et al. Materials Today Communications 33 (2022) 104912
The vibrational characteristics of tested specimens were determined 3. Results and discussions
with an impulse hammer test. The purpose of conducting these tests is to
determine the natural frequencies and structural constants of different 3.1. Flexural strength tests results
specimens. These constants are equivalent masses (m), spring constants
(k), structural damping ratios, and natural frequencies (ωn) of the sys All the mechanical tests were conducted at room temperature ac
tem. In order to conduct the test, the specimens were clamped from one cording to ASTM D790 standard. For all groups, at least three specimens
side with a vise, as shown in Fig. 6. The natural frequency test was were tested in each group, and flexural strength and flexural modulus
performed by connecting the accelerometer to the left side of the spec were calculated per the equations given in (II) and (III). Fig. 8 shows the
imens and hitting the opposite side with an impulse hammer. Structural load and displacement curves of Tri-hexagon pattern specimens with
constants were obtained by processing the data with Cut Pro 8.0 soft different infill ratios. As the infill ratio increases, the load-bearing ca
ware. The dimensions of the studied specimens are given in Fig. 7. In pacity of specimens increases as expected. Similarly, the flexural
order to have reliable results, five perfect hits are required modulus of specimens increases as the infill ratio increases. This trend is
4
M.Ö. Öteyaka et al. Materials Today Communications 33 (2022) 104912
pattern was the Cross pattern. At higher infill ratios (80 %, 100 %),
the Tri-hexagon pattern gives higher strength, while at lower infill ratios
(20 %, 40 %, 60 %) Grid pattern shows better flexural strength. These
two patterns show quite close flexural strengths. For the same infill ra
tios, the ultimate flexural strength differences among different patterns
are quite low. The difference between low performing cross pattern and
high performing Tri-hexagon pattern was the highest difference
observed in the 60 % infill ratio (11 %), and the lowest difference was
observed in the 20 % infill ratio (4 %).
As the infill ratio increased from 0 % to 100 % in the Tri-hexagon
pattern, flexural strength can be improved by 77 %. Similarly, the
Fig. 7. Schematically representation of modal tests.
flexural modulus value also increases as the infill ratio increases, and the
material shows a more rigid characteristic. Table 4 shows the calculated
Table 3 flexural modulus of test samples.
Boundry condition for the transverse vibration of a beam (n: mode shapes). Tri-hexagon gives the highest strength among the tested infill pat
terns, and the grid performs close to it and Cross in all conditions.
End conditions of beam Frequency equation Value of βnl
However, the weight of the specimen and the resources required the
cos βnl.cosh βnl= − 1 β1l = 1.875104 produce this specimen also increased. In order to find the optimum infill
β2l = 4.694091
ratio and pattern, a configuration should perform high flexural strength
β3l = 7.854757
β4l = 10.995541 with low specimen weight; as the infill ratio of the flexural bending
specimens increases in all patterns, the UTS value increases. As the
amount of added material increases, the increase in strength obtained
gradually decreases. In order to compare the benefit of added material
on flexural strength specifically, UTS was calculated. The specific ulti
mate flexural strength of specimens was calculated by dividing the UTS
by the density of specimens. Fig. 10 shows the specific ultimate flexural
Fig. 8. Load and Displacement curve of bending test for different infill ratios of
Tri-hexagon pattern.
5
M.Ö. Öteyaka et al. Materials Today Communications 33 (2022) 104912
Table 4 same volume of 3D-printed specimens contains PLA, and the cavity is
The calculated flexural modulus of specimens (GPa). filled with air; as the infill ratio increases, the amount of PLA on the
Infill Ratio % Cross Grid Trihex structure increases, so the flexural modulus becomes closer to the bulk
material properties of PLA. As the air inside of samples does not
0 2.15 2.12 2.14
20 2.46 2.42 2.42 contribute to any flexural property, but it lowers the density, the flexural
40 2.82 2.58 2.66 properties can be correlated with specimen density. Since the produc
60 2.98 2.98 2.90 tion parameters (substrate temperature, melting outlet temperature,
80 3.23 3.14 3.14 advance rate, etc.) are the same for the PLA materials produced, it can be
100 3.27 3.23 3.23
said that the rigidity will increase as the infill ratio increases for the
specimens with different infill ratios. On the other hand, due to the
strength of specimens. According to the specific strength results, it can nature of additive manufacturing, it can be said that the cooling of the
be said that it is beneficial to add a support structure to the hollow specimen with a tighter fill will be a little slower, and this may affect the
structure. The specific flexural strength value obtained in all support mechanical properties to a certain extent. In AM, density is a crucial
structures increased. The specific strength value obtained for the 20 % parameter that can indicate many issues in the design and
fill rate for all patterns was observed as maximum. The differences manufacturing process. The density measurement is also a measurement
observed according to the infill patterns are quite low. In general, after a of internal voids and flaws.
40 % infill ratio, a decrease is observed in the specific flexural strength
values. According to these results, the use of an infill pattern increases 3.2. Modal analysis
flexural strength, and the improvement in mechanical properties in
creases, especially according to the amount of material added up to 40 Fig. 11 shows the damping ratio vs. infill ratio values for all tested
%. After a 40 % infill ratio, it can be said that the increase in strength patterns. Experimentally obtained damping ratio values show that the
against the added additional material decreases. There is practically no Cross pattern shows the best vibration-damping behavior among tested
infill pattern in the specimens expressed as 0 %. It consists only of the patterns. Tri-hexagon pattern showed slightly better vibration damping
walls and the gap in the middle. On the other hand, we can say that the compared to Grid patterns; it can be said that the results are quite close
100 % filled ones are completely filled by following the relevant pattern. to each other. It can be said that the Cross pattern’s relatively complex
Similar trends were obtained in the literature after 40 % infill ratio [10]. shape helped dampen vibrations by extending the path for vibration
Dobos and Oldal have studied ISO 178 concentric, Hilbert, and honey signals compared to more regular patterns such as the Grid Pattern.
comb and rectilinear patterns of PLA polymers, and they observed that Regarding the effect of the infill ratio, a similar trend was obtained
specific load capacity increases when the infill ratio increases from 40 % between the infill ratio and damping ratio in all patterns. The highest
to 100 % infill ratio. The load capacity efficiency increases at a filling damping ratio was obtained at a 40 % infill ratio in all patterns. The
density of 40 %, regardless of the filling pattern. It can be said that the damping properties of the tested PLA material are considered to be
results of the study are consistent with the literature in this regard. better than many structural materials. Therefore, increasing the amount
According to these results, it can be said that the infill pattern has an of material up to a 40 % rate improved the damping ability, but after this
effect on the flexural strength and flexural modulus, and using a 20 % or point, increasing the infill ratio decreased the damping ability.
40 % support structure compared to the hollow structure provides sig Modal analysis results showed that the infill pattern and infill ratio
nificant benefits over the bending properties. also significantly affect the modal characteristics of specimens.
It can be said that the material properties are very close to each other Choosing the right pattern and infill ratio might improve the damping
since all of the tested specimens were produced by melting the same ratio by a factor of 3. Similarly, the infill pattern and ratio alter the
material under the same conditions. When we investigated the flexural natural frequency. In Fig. 12, the relationship between natural fre
modulus, the flexural modulus increased as expected as the infill ratio quency and infill ratio in different patterns is given. Generally, rigidity
increased in all groups. Dudescu et al. l explained this situation with the increases with an increasing natural frequency. The natural frequency
rule of the mixture used in composite materials [27]. The rule of the values are the highest in all patterns at an 80 % infill ratio, and it is seen
mixture is used to determine the properties of a composite material by that the trends are similar in all patterns. In general, the natural fre
considering the volumetric fraction of components. The content of the quency values are higher in the grid pattern. Higher natural frequency
values were obtained in the Tri-hexagonal pattern compared to the cross
Fig. 11. The relation between the damping ratio and infill ratio of
Fig. 10. Specific ultimate flexural strength of specimens. different patterns.
6
M.Ö. Öteyaka et al. Materials Today Communications 33 (2022) 104912
Fig. 13. Frequency response functions (FRF) at 80 % infill ratio for different patterns.
7
M.Ö. Öteyaka et al. Materials Today Communications 33 (2022) 104912
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