Session: Research Posters

Paper Number: 173741

Analyzing the Impact of Infill Percentage on Mechanical Properties of 3d Printed Dog Bone Samples Made From Pla and Petg 

The advent of 3D printing technology has dramatically transformed manufacturing processes across a wide range of industries, offering unprecedented levels of customization, speed, and cost efficiency. Despite its widespread adoption, there remains a limited understanding of the mechanical properties of the materials employed during the 3D printing process, which is critical for ensuring the reliability and durability of printed components. This study focuses on evaluating the mechanical properties of 3D-printed samples, specifically using polylactic acid (PLA) and polyethylene terephthalate glycol (PETG) materials, with varying infill percentages to determine how infill density impacts performance.

The research involved fabricating dog bone-shaped test samples from PLA and PETG using standard 3D printing methods. The samples were printed with six distinct infill percentages: 10%, 20%, 40%, 60%, 80%, and 100%. Two sets of tests were conducted, one for each material type, to ensure a comprehensive analysis. The samples were subjected to tensile testing, during which data from extensometers and force sensors were collected and analyzed. This data was compiled into Excel spreadsheets to calculate a variety of key material properties, including Modulus of Elasticity, Ductility, Elastic Strain Energy, Resilience, Toughness, as well as Tensile, Yield, and Fracture Strengths.

The findings reveal that the mechanical properties of 3D-printed materials are significantly influenced by infill density. As the infill percentage increases, the materials exhibit enhanced mechanical properties such as greater strength, toughness, and resilience. However, this improvement is not linear; the properties tend to stabilize beyond a certain infill threshold, referred to as the saturation point. This saturation point is material-dependent, varying between PLA and PETG. For instance, PLA may exhibit a saturation point at a lower infill percentage compared to PETG, reflecting inherent differences in the material structures and their responses to stress.

These results have important implications for the design and optimization of 3D-printed components. By understanding the relationship between infill density and material performance, engineers and designers can make informed decisions to achieve desired mechanical properties while minimizing material usage and production time. This study provides valuable insights into the mechanical behavior of 3D-printed materials, contributing to the growing body of knowledge necessary for advancing 3D printing technology and its applications across diverse fields. Future research could further explore the effects of other variables, such as printing orientation, layer height, and environmental conditions, to fully optimize the potential of 3D printing materials and processes. The increasing versatility of 3D printing continues to inspire innovation globally.

Presenting Author: Jack Fisher Kansas State University

Presenting Author Biography: Jack is a Mechanical Engineer and graduated from Kansas State University

Authors:

Jack Fisher Kansas State University
Mohammadhosein Ghasemi Baboly Kansas State University