Session: 02-07-01: Design for AM and Sustainability

Paper Number: 163971

Improving Impact Resistance in 3D-Printed Structures Through Parameter Optimization 

Additive manufacturing (AM) has rapidly emerged as a transformative technology in today's industry. One popular AM method that has become increasingly popular in today's industries is fused deposition modeling (FDM). Compared to conventional subtractive manufacturing techniques, this layer-by-layer fabrication method allows for the creation of complex geometries with less material waste. Even though FDM has many benefits, issues with the mechanical performance, optimization, and failure predictability of printed parts are preventing it from being widely used. It is challenging to achieve consistent mechanical properties due to the nature of FDM-manufactured components, which is influenced by printing parameters. As a result, its suitability for high-production applications that require similar or nearly uniform strength across every component of the manufacturing part is limited. Printing orientation, speed, temperature, raster angle, infill density, infill pattern, overlap ratio and nozzle diameter are some of the critical factors that affect the mechanical behavior of FDM-printed parts. To improve the structural integrity of printed components and optimize FDM processes, it is crucial to comprehend how these factors relate to one another. The raster angle and infill density are two of these variables that are most important in influencing the mechanical strength of components that are subjected to impact loads. Infill density is the amount of material deposited within a part, which influences its internal structure and resistance to mechanical forces. Conversely, raster angle determines the orientation of printed layers and affects the distribution of stress throughout the component. This study examines how raster angle and infill density affect parts made of polylactic acid (PLA) and polyethylene terephthalate glycol (PETG) during impact loading. Specimens were produced with different infill densities of 25%, 50%, 75%, and 100%, and three separate raster angle arrangements of 0°-90°, 30°-60°, and 45°-45° were also investigated, resulting in a total of 12 unique specimens. The impact strength of each sample was tested to analyze the relationship between infill density, raster angle, and material performance under impact conditions. The findings reveal that an increase in infill density correlates with higher impact strength, as specimens with higher infill density demonstrate better fracture resistance. Furthermore, among specimens with the same infill density, those manufactured with a 30°-60° raster angle exhibited better impact resistance than the others. This indicates that optimizing raster angle configurations could improve energy absorption and stress distribution in parts produced with FDM technology. These results provide important understanding regarding the mechanical enhancement of FDM components, which may enhance their use in sectors that demand durable, impact-resistant materials. Future studies will investigate the fabrication and optimization of powder-based feedstocks for metal and ceramic additive manufacturing, focusing on compounding techniques, particle size distribution, and material characterization.

 

Presenting Author: Mechack Nduwa Kennesaw State University

Presenting Author Biography: My name is Mechack Nduwa, and I am a graduate student attending Kennesaw State University (KSU), pursuing a Ph.D. in Interdisciplinary Engineering with a concentration in Innovative Materials. I am passionate about additive manufacturing, with a strong interest in feedstock fabrication and the mechanical optimization of 3D-printed materials. My goal is to further my knowledge and research by attending and participating in conferences while contributing to advancements in FDM processes. Presently, I plan to continue my research at Idaho National Laboratory, focusing on material development for additive manufacturing.

Authors:

Aaron Adams Kennesaw State University
Mechack Nduwa Kennesaw State University
Edgar Bryant Kennesaw State University
David Stollberg Kennesaw State University
Cameron Coates Kennesaw State University