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Post-Print Annealing of FDM-Printed Polylactic Acid: Mapping Strength, Crystallinity, and α'/α Polymorph Composition

Walid M Shewakh1, Majed H Moosa1, Zainab Hussain2

  • 1Department of Industrial Engineering, College of Engineering and Computer Sciences, Jazan University, Jazan 82817, Saudi Arabia.

Polymers
|June 12, 2026
PubMed
Summary

Annealing fused deposition modeling (FDM) printed polylactic acid (PLA) significantly improves tensile strength by increasing crystallinity. Moderate annealing conditions optimize crystal content and polymorph character for enhanced performance.

Keywords:
ANOVADSCTaguchi methodXRDannealingcrystallinityfused deposition modelingmultivariate regressionpolylactic acidtensile strengthα′/α polymorphism

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Area of Science:

  • Materials Science
  • Polymer Engineering
  • Additive Manufacturing

Background:

  • Fused Deposition Modeling (FDM) of polylactic acid (PLA) parts exhibit limited tensile performance due to poor interlayer bonding and low as-printed crystallinity.
  • Optimizing post-processing techniques like annealing is crucial for enhancing the mechanical properties of FDM-printed PLA components.

Purpose of the Study:

  • To investigate the effects of annealing temperature and holding time on the tensile properties and crystallinity of FDM-printed PLA.
  • To establish a relationship between annealing parameters, crystal structure (polymorph fractions), and ultimate tensile stress (UTS).
  • To identify optimal annealing conditions for maximizing the tensile performance of commercial PLA grades.

Main Methods:

  • Utilized a Taguchi L9 orthogonal array design for systematic variation of annealing temperature (70-90 °C) and holding time (40-80 min).
  • Employed Differential Scanning Calorimetry (DSC) and X-ray Diffraction (XRD) to quantify total crystallinity and analyze polymorph fractions (α' and α).
  • Performed tensile testing on annealed and non-annealed specimens to evaluate ultimate tensile stress (UTS).

Main Results:

  • All annealing conditions resulted in improved UTS compared to the non-annealed baseline (39.75 ± 1.28 MPa).
  • Optimal performance was achieved at 70 °C for 60 min, yielding an UTS of 47.00 ± 0.97 MPa (18.2% increase).
  • Total crystallinity increased from 8.6% (baseline) to 41.8% (90 °C/80 min), with consistent rankings between DSC and XRD.
  • ANOVA indicated significant contributions from both annealing temperature (30.0%) and time (24.2%).
  • High-performance specimens were dominated by the disordered α' polymorph, while higher temperatures favored the stiffer α polymorph.

Conclusions:

  • Annealing significantly enhances the tensile strength of FDM-printed PLA by increasing total crystallinity and influencing polymorph composition.
  • Moderate annealing temperatures just above the glass transition provide the best balance of crystal content, polymorph character, and dimensional stability.
  • A combined strength-crystallinity-polymorph map is proposed, highlighting the critical role of polymorph fractions beyond total crystallinity in determining mechanical properties.