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

The article discusses the importance of optimizing process parameters in 3D printing to achieve better mechanical properties of printed parts. It emphasizes the material extrusion 3D printing technology and some of the most commonly used materials, acrylonitrile butadiene styrene (ABS) and polyethylene terephthalate glycol (PETG). Optimizable process parameters such as, print angle, outer layer number, extruder flow ratio, extrusion (nozzle) temperature, and layer thickness are examined. The article also highlights the importance of postprocessing techniques, specifically thermal postprocessing (annealing) and chemical postprocessing in the acetone (AC) chamber, to enhance mechanical properties of printed parts. The results show that the wall structures played a crucial role in defining mechanical properties, acting as main load-bearing elements. Adjusted flow ratios influenced mechanical properties. Samples with a 25% extruder flow rate increase demonstrated a 44% rise in elongation at break, while a 50% increase led to slight strength reduction. The ABS material AC-treated sample exhibited 58.2% lower tensile strength and 1.9% lower elongation due to stress concentration, while thermally treated showed similar results to the default, printed at manufacturer-recommended settings. The PETG material AC-treated sample exhibited 53.2% lower tensile strength, but 17.5% higher elongation, while thermally treated showed similar results to the default. Samples printed at 0° orientation exhibited plastic deformation with the highest tensile strength and elongation, while samples at 45° and 90° orientations experienced delamination, leading to brittle fracture, proving that the orientation and interlayer adhesion have a great influence on mechanical properties. While the print settings and orientation had similar effects on mechanical properties of each material, postprocessing effects are greatly influenced by the polymer matrix.