This article explores the optimization of 3D printing parameters of PLA/wood dust (PLA/WD) composite material for enhanced physical properties, including density, surface roughness, water absorption, and Shore D hardness. The study employs a Taguchi-based L27 orthogonal array design for experimentation, with mathematical models created using grey relational analysis (GRA) to predict the material’s performance by obtaining a grey relational grade (GRG). The obtained GRG was further optimized using ANOVA. The FFF input parameters analyzed include nozzle temperature (190–200°C), layer height (0.12–0.28 mm), print speed (30–50 mm/min), infill density (80–100%), and raster angle (0–90°). The results indicate that a printing temperature of 195°C, a layer thickness of 0.12 mm, a print speed of 30 mm/sec, 100% infill density, and a raster angle of 45° yield the highest GRG, signifying the best overall performance. Furthermore, the data obtained from Analysis of Variance (ANOVA) indicated that, raster angle has the most substantial influence on physical characteristics, followed by infill %, print speed, print temperature, and layer thickness. The investigation of the sample using Scanning Electron Microscopy (SEM) revealed aspects of the sample morphology, including layer bonding irregularities and empty spaces, which impact the density and hardness of the material.
MishraVNegiSKarS. Additive manufacturing: an emerging tool to fabricate bioinspired structures. In: SudarshanTSPandeyKMMisraRD, et al. (eds) Recent Advancements in Mechanical Engineering, ICRAME 2021. Singapore: Springer, 2021, pp. 297–312.
2.
MishraVNegiSKarS. FDM-based additive manufacturing of recycled thermoplastics and associated composites. J Mater Cycles Waste Manag2023; 25: 758–784. DOI: 10.1007/s10163-022-01588-2.
3.
MishraVNegiSKarS, et al.Recent advances in fused deposition modeling based additive manufacturing of thermoplastic composite structures: a review. J Thermoplast Compos Mater2022; 36: 3094–3132. DOI: 10.1177/08927057221102857.
RigginsAWDadmunMD. Controlling residual stress in material extrusion 3D printing through material formulation. Addit Manuf2023; 73: 103678. DOI: 10.1016/j.addma.2023.103678.
6.
KrajangsawasdiNLonganaMLHamertonI, et al.Batch production and fused filament fabrication of highly aligned discontinuous fibre thermoplastic filaments. Addit Manuf2021; 48: 102359. DOI: 10.1016/j.addma.2021.102359.
7.
WangXHuangLLiY, et al.Research progress in polylactic acid processing for 3D printing. J Manuf Process2024; 112: 161–178. DOI: 10.1016/j.jmapro.2024.01.038.
8.
JosephTMKallingalASureshAM, et al.3D printing of polylactic acid: recent advances and opportunities. Int J Adv Manuf Technol2023; 125: 1015–1035. DOI: 10.1007/s00170-022-10795-y.
9.
MishraVRorCKNegiS, et al.Development of sustainable 3D printing filaments using recycled/virgin ABS blends: processing and characterization. Polym Eng Sci2023; 63: 1890–1899. DOI: 10.1002/pen.26330.
10.
WangPZouBDingS, et al.Effects of FDM-3D printing parameters on mechanical properties and microstructure of CF/PEEK and GF/PEEK. Chin J Aeronaut2021; 34: 236–246. DOI: 10.1016/j.cja.2020.05.040.
11.
KhosravaniMRSchüürmannJBertoF, et al.On the post-processing of 3D-printed ABS parts. Polymers2021; 13: 13101559. DOI: 10.3390/polym13101559.
12.
ValvezSSilvaAPReisPNB. Optimization of printing parameters to maximize the mechanical properties of 3D-printed PETG-based parts. Polymers2022; 14: 2564.
MaheshVGeorgeJPMaheshV, et al.Dry-sliding wear properties of 3D printed PETG/SCF/OMMT nanocomposites: experimentation and model predictions using artificial neural network. J Reinforc Plast Compos2023; 43: 682–693. DOI: 10.1177/07316844231188853.
15.
RorCKNegiSMishraV. Development and characterization of sustainable 3D printing filaments using post-consumer recycled PET: processing and characterization. J Polym Res2023; 30: 350. DOI: 10.1007/s10965-023-03742-2.
16.
KumarJNegiS. Development of 3D printable cenosphere-reinforced polyethylene terephthalate glycol (PETG) filaments for lightweight structural applications. Polym Compos2023; 44(10): 7030–7039. DOI: 10.1002/pc.27616.
17.
FangLYanYAgarwalO, et al.Processing-structure-property relationships of bisphenol-A-polycarbonate samples prepared by fused filament fabrication. Addit Manuf2020; 35: 101285. DOI: 10.1016/j.addma.2020.101285.
18.
KumarSRameshMRDoddamaniM, et al.Mechanical characterization of 3D printed MWCNTs/HDPE nanocomposites. Polym Test2022; 114: 107703. DOI: 10.1016/j.polymertesting.2022.107703.
19.
YilmazS. Comprehensive analysis of 3D printed PA6.6 and fiber-reinforced variants: revealing mechanical properties and adhesive wear behavior. Polym Compos2024; 45: 1446–1460. DOI: 10.1002/pc.27865.
20.
DuaRRashadZSpearsJ, et al.Applications of 3D-printed PEEK via fused filament fabrication: a systematic review. Polymers2021; 13: 4046.
21.
MikulaKSkrzypczakDIzydorczykG, et al.3D printing filament as a second life of waste plastics—a review. Environ Sci Pollut Res2020; 28: 12321–12333. DOI: 10.1007/s11356-020-10657-8.
22.
AliFKalvaSNMroueKH, et al.Degradation assessment of Mg-incorporated 3D printed PLA scaffolds for biomedical applications. Bioprinting2023; 35: e00302. DOI: 10.1016/j.bprint.2023.e00302.
23.
AlamMMEzhilanMSahaS, et al.Design, fabrication, mechanical, and in vitro evaluation of 3D printed ZrO2 reinforced polylactide scaffolds through fused deposition modeling. Mater Chem Front2023; 7: 464–475. DOI: 10.1039/D2QM01014C.
24.
JayanthNSenthilP. Application of 3D printed ABS based conductive carbon black composite sensor in void fraction measurement. Composites Part B2019; 159: 224–230. DOI: 10.1016/j.compositesb.2018.09.097.
TomecDKSchwarzkopfMRepičR, et al.Effect of thermal modification of wood particles for wood-PLA composites on properties of filaments, 3D-printed parts and injection moulded parts. Eur J Wood Prod2023; 82(2): 403–416. DOI: 10.1007/s00107-023-02018-2.
27.
YuWLiMLeiW, et al.Effects of wood flour (WF) pretreatment and the addition of a toughening agent on the properties of FDM 3D-printed WF/poly(lactic acid) biocomposites. Molecules2022; 27: 2985.
28.
AyrilmisNKarižMKitek KuzmanM. Effect of wood flour content on surface properties of 3D printed materials produced from wood flour/PLA filament. Int J Polym Anal Char2019; 24: 659–666. DOI: 10.1080/1023666X.2019.1651547.
29.
ShanmugamVRajendranDJJBabuK, et al.The mechanical testing and performance analysis of polymer-fibre composites prepared through the additive manufacturing. Polym Test2021; 93: 106925. DOI: 10.1016/j.polymertesting.2020.106925.
30.
LiHWangTSunJ, et al.The effect of process parameters in fused deposition modelling on bonding degree and mechanical properties. Rapid Prototyp J2018; 24: 80–92. DOI: 10.1108/RPJ-06-2016-0090.
31.
Heidari-RaraniMEzatiNSadeghiP, et al.Optimization of FDM process parameters for tensile properties of polylactic acid specimens using Taguchi design of experiment method. J Thermoplast Compos Mater2020; 35(12): 2435–2452. DOI: 10.1177/0892705720964560.
32.
ChariVSVenkateshPRKrupashankar, et al.Effect of processing parameters on FDM process. AIP Conf Proc2018; 1943: 020061. DOI: 10.1063/1.5029637.
33.
LokeshNPraveenaBASudheer ReddyJ, et al.Evaluation on effect of printing process parameter through Taguchi approach on mechanical properties of 3D printed PLA specimens using FDM at constant printing temperature. Mater Today Proc2022; 52: 1288–1293. DOI: 10.1016/j.matpr.2021.11.054.
34.
KamMIpekçiAŞengül. Taguchi optimization of fused deposition modeling process parameters on mechanical characteristics of PLA + filament material. Sci Iran2022; 29: 79–89. DOI: 10.24200/sci.2021.57012.5020.
35.
ShakeriZBenfrihaKZirakN, et al.Mechanical strength and shape accuracy optimization of polyamide FFF parts using grey relational analysis. Sci Rep2022; 12: 13142. DOI: 10.1038/s41598-022-17302-z.
36.
VenkatasubbareddyOYSiddikaliPSaleemSM. Improving the dimensional accuracy and surface roughness of fdm parts using optimization techniques. IOSR J Mech Civ Eng2016; 16: 18–22. DOI: 10.9790/1684-16053041822.
37.
PulipakaAGideKMBeheshtiA, et al.Effect of 3D printing process parameters on surface and mechanical properties of FFF-printed PEEK. J Manuf Process2023; 85: 368–386. DOI: 10.1016/j.jmapro.2022.11.057.
38.
JohnJDevjaniDAliS, et al.Optimization of 3D printed polylactic acid structures with different infill patterns using Taguchi-grey relational analysis. Adv Ind Eng Polym Res2023; 6: 62–78. DOI: 10.1016/j.aiepr.2022.06.002.
39.
MathiazhaganNSivakumarNKPalaniyappanS, et al.Influence of printing-based factors on the mechanical properties of hexagonal lattice-structured 3D printed novel walnut shell/polylactic acid composite. J Thermoplast Compos Mater2023; 37(2): 713–742. DOI: 10.1177/08927057231185711.
40.
KumarPGuptaPSinghI. Optimisation of extrusion process parameters to make ABS-PC filament for 3D printing using Taguchi-GRA technique. Adv Mater Process Technol2023; 10(3): 1921–1922. DOI: 10.1080/2374068X.2023.2204458.
41.
KechagiasJDZaoutsosSP. Optimising fused filament fabrication surface roughness for a dental implant. Mater Manuf Process2023; 38: 954–959. DOI: 10.1080/10426914.2023.2176870.
42.
MishraVKumarABhattNK, et al. Parametric optimisation of 3D-printed PLA/wood dust composite for load-bearing application using grey relational analysis. Proc Inst Mech Eng Part E J Process Mech Eng. 2024; 09544089241241460. DOI:10.1177/09544089241241460.
43.
JozićSBajićDCelentL. Application of compressed cold air cooling: achieving multiple performance characteristics in end milling process. J Clean Prod2015; 100: 325–332. DOI: 10.1016/j.jclepro.2015.03.095.
Supplementary Material
Please find the following supplemental material available below.
For Open Access articles published under a Creative Commons License, all supplemental material carries the same license as the article it is associated with.
For non-Open Access articles published, all supplemental material carries a non-exclusive license, and permission requests for re-use of supplemental material or any part of supplemental material shall be sent directly to the copyright owner as specified in the copyright notice associated with the article.
