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Maximizing Mechanical Performance of 3D Printed Parts Through Process Parameter Optimization.

Marijan-Pere Marković1, Ivan Karlo Cingesar1, Domagoj Vrsaljko1

  • 1Department of Thermodynamics, Mechanical Engineering and Energy, University of Zagreb, Faculty of Chemical Engineering and Technology, Zagreb, Croatia.

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Summary
This summary is machine-generated.

Optimizing 3D printing parameters and postprocessing significantly enhances mechanical properties. Print orientation and flow ratio adjustments are key for acrylonitrile butadiene styrene (ABS) and polyethylene terephthalate glycol (PETG) parts.

Keywords:
additive manufacturingmaterial extrusionmechanical propertiespostprocessing techniquesprocess parameters

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Area of Science:

  • Materials Science and Engineering
  • Additive Manufacturing
  • Polymer Science

Background:

  • Material extrusion 3D printing is widely used for polymer parts.
  • Achieving desired mechanical properties requires careful control of printing and postprocessing parameters.
  • Acrylonitrile butadiene styrene (ABS) and polyethylene terephthalate glycol (PETG) are common 3D printing materials with distinct characteristics.

Purpose of the Study:

  • To investigate the impact of optimizing process parameters on the mechanical properties of 3D printed parts.
  • To evaluate the effectiveness of thermal and chemical postprocessing techniques on ABS and PETG.
  • To determine the influence of print orientation and interlayer adhesion on material performance.

Main Methods:

  • Exploration of key process parameters: print angle, outer layer number, extruder flow ratio, extrusion temperature, and layer thickness.
  • Application of postprocessing techniques: thermal annealing and acetone (AC) chemical treatment.
  • Mechanical property testing including tensile strength and elongation at break for modified and control samples.

Main Results:

  • Wall structures critically influence mechanical properties, acting as primary load-bearing elements.
  • Adjusted flow ratios significantly impact mechanical performance; a 25% increase in flow rate enhanced elongation at break by 44% in ABS.
  • Print orientation drastically affects properties; 0° orientation yielded highest strength and elongation, while 45° and 90° resulted in delamination and brittle fracture.

Conclusions:

  • Process parameter optimization, particularly print orientation and flow ratio, is crucial for tailoring mechanical properties in ABS and PETG 3D prints.
  • Postprocessing effects are polymer-dependent; acetone treatment impacted ABS and PETG differently, while thermal annealing showed less pronounced effects.
  • Interlayer adhesion, influenced by orientation and processing, is a critical factor for achieving robust mechanical performance in 3D printed components.