Infill structure analysis of FDM-printed PLA wood glass fiber composite for commercial product applications

Abstract In this study, the mechanical properties of triangular and honeycomb infill structures with varying percentages (20%, 40%, and 60%) of 3D printed polylactic acid (PLA) wood-glass fiber for bi-directional reinforcement are explored. The objective is to assess these structures under different loading conditions and select the most suitable configuration for practical applications. Flexural strength, hardness, impact, tensile strength and scanning electron microscope analysis of fracture morphology were conducted on a range of mechanical tests. In addition, thermal conductivity, V-notch rail shear strength and wear resistance tests were performed. Structural integrity, resilience, material durability, heat transfer, adhesive properties, and fracture behavior are tested, and a complete analysis of performance is performed. Form the results, honeycomb structures with 60% infill demonstrated a high strength-to-weight ratio, offering potential for lightweight structural components across various sectors. Their lightweight yet robust nature enhances overall performance. Meanwhile, triangular structures with 40% infill showcased competitive mechanical properties and efficient load distribution, making them suitable for lightweight sporting equipment, furniture, protective gear, and safety equipment. At higher infill percentages, both honeycomb and triangle infill patterns are found to provide increased wear resistance to density ratios for automotive components (gears, brake pads), aerospace parts (landing gear, engine components), industrial machinery (bearings, pulleys), and consumer electronics (wearable devices, protective casings) where wear resistance and durability under friction are critical.