Pattern optimization for 3D printing of composite filament materials with natural fibers and polylactic acid

Abstract

Composite fiber materials developed through Fused Deposit Modeling (FDM) in high demand in fabricating automotive, machinery components such as bearings, sleeves, bumpers, windshields, etc. In this article, a new composite filament with natural fiber (Flax) and polylactic acid was prepared and their mechanical properties were analyzed. Taguchi approaches L27 orthogonal array was used to optimize the process parameters layer thickness (0.15, 0.25, 0.35 mm) for 0.4 mm nozzle with filling structure (L1—lines, L2—triangles, L3—octet), speed of nozzle movement (80,100,120 mm/s) and occupancy ratios (20%, 40%, 60%) were chosen as process parameters. Tensile and Impacts test have been carried with American Society of Testing and Materials Standard (ASTM D638 and ASTM D256) to evaluate the tensile strength, percentage of elongation and impacts strength of the fabricated specimens. The results emphasized that layer thickness significant influences the tensile characteristics as compared to better process parameters. The occupancy ratio at 20% and 40% with triangle and octet filling structure, nozzle speed of 100 mm/s at constant extruder temperature of 200°C have been found to optimize 3D printing parameters in this work. They were calculated as tensile strength 61.13 MPa, percentage of elongation is 4.43% and Izod impact test is 12.77 kJ/m².