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Enhancing 3D Printing Copper-PLA Composite Fabrication via Fused Deposition Modeling through Statistical Process
Mahmoud Moradi1, Omid Mehrabi2, Fakhir A Rasoul3
1Faculty of Arts, Science and Technology, University of Northampton, Northampton NN1 5PH, UK.
Micromachines
|September 28, 2024
Summary
This study optimized fused deposition modeling (FDM) for Copper-Polylactic Acid (Cu-PLA) composites. Optimal settings for layer thickness, infill percentage, and pattern were identified to enhance mechanical properties and minimize weight for 3D printed parts.
Area of Science:
- Materials Science and Engineering
- Additive Manufacturing
- 3D Printing
Background:
- Additive Manufacturing (AM) technologies enable complex 3D part fabrication.
- Fused Deposition Modeling (FDM) extrudes polymer-metal composite filaments.
- Copper-Polylactic Acid (Cu-PLA) combines copper's conductivity with PLA's processability.
Purpose of the Study:
- Investigate the impact of FDM parameters on Cu-PLA composite parts.
- Analyze effects on maximum failure load, elongation at break, and weight.
- Determine optimal process parameters for enhanced material performance.
Main Methods:
- Utilized Copper-Polylactic Acid (Cu-PLA) filament in FDM 3D printing.
- Employed Response Surface Methodology (RSM) with Design-Expert V11 software.
- Varied infill percentage (10-50%), infill patterns (Grid, Triangle, etc.), and layer thickness (0.1-0.5 mm).
Main Results:
- Layer thickness and infill percentage significantly increase sample weight.
- Higher layer thickness and infill percentage enhance maximum failure load.
- Maximum failure load of 230 N achieved at 0.5 mm layer thickness and Tri-Hexagonal pattern.
Conclusions:
- Elongation at break decreases with increasing infill percentage.
- Optimal settings for maximum elongation at break identified.
- Multi-objective optimization yielded ideal parameters: 0.152 mm layer thickness, 32.909% infill, and Grid pattern.
