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Enhancing PLA Strength and Layer Adhesion: Physical and Microstructural Insights from Vibration-Assisted FFF/FDM
Lotfi Ben Said1, Fouzi Alhadar2, Hamdi Hentati3,4
1Department of Mechanical Engineering, College of Engineering, Scientific and Engineering Research Center, University of Ha'il, Ha'il 55473, Saudi Arabia.
Polymers
|July 28, 2026
Summary
Controlled low-frequency bed vibration significantly enhances the mechanical properties and reduces porosity in 3D-printed PLA components. This simple additive manufacturing technique improves quality and reliability for polymer parts.
Area of Science:
- Additive Manufacturing
- Materials Science
- Polymer Engineering
Background:
- Material Extrusion (MEX), including Fused Filament Fabrication (FFF)/Fused Deposition Modeling (FDM), is widely used for polymer components.
- Key limitations include weak interlayer bonding and internal porosity, hindering mechanical performance.
- Optimizing FFF/FDM processes is crucial for advancing polymer manufacturing.
Purpose of the Study:
- To investigate the impact of controlled low-frequency bed vibration on PLA components produced via FFF/FDM.
- To evaluate how printing speed, raster angle, and vibration level affect physical and mechanical properties.
- To optimize process parameters for improved tensile strength, yield strength, flexural strength, and surface quality.
Main Methods:
- Experimental evaluation of PLA components using tensile, flexural, and surface roughness tests.
- Material characterization via Fourier Transform Infrared Spectroscopy (FTIR) and Scanning Electron Microscopy (SEM).
- Optimization of process parameters using Response Surface Methodology (RSM).
Main Results:
- Moderate bed vibration (Level 2) improved mechanical properties by 8-15% compared to conventional printing.
- SEM analysis showed a ~60% reduction in average pore size and enhanced filament fusion/interlayer adhesion.
- FTIR confirmed no changes in the chemical structure of PLA.
Conclusions:
- Controlled mechanical bed vibration is an effective strategy to enhance the quality, reliability, and structural performance of FFF/FDM-printed PLA.
- The findings offer practical guidelines for optimizing additive manufacturing processes.
- This approach supports the development of advanced polymer manufacturing capabilities.
