Improving the strength properties of PLA acetabular liners by optimizing FDM 3D printing: Taguchi approach and finite element analysis validation

Abstract This study investigates the enhancement of polylactic acid (PLA) mechanical properties through the optimization of fused deposition modeling (FDM) 3D printing parameters for potential use in acetabular liner implants. The Taguchi method was employed to systematically evaluate the influence of nozzle temperature, printing speed, layer thickness, and raster orientation, enabling the identification of optimal printing conditions. Specimens were prepared according to ASTM D638 standards and subjected to tensile testing and finite element analysis (FEA) to validate the optimization process. Data analysis using Minitab software revealed that the optimal parameters nozzle temperature of 210 °C, print speed of 30 mm/s, layer thickness of 0.1 mm, and raster orientation of 0° resulted in Young’s modulus of up to 3400 MPa and ultimate tensile strength of 51 MPa. Additionally, scanning electron microscopy (SEM) analysis was conducted to assess the microstructural integrity of the printed specimens, revealing well-defined filament interfaces and minimal porosity, which contributed to the enhanced mechanical performance. These findings indicate that optimized PLA exhibits mechanical properties comparable to those of conventional implant materials, thereby providing a biocompatible, cost-effective, and customizable alternative for acetabular liner applications. The study further confirms the ability of optimized PLA implants to safely support body weights of 70, 80, and 90 kg, contributing significantly to the development of advanced, affordable solutions in orthopedic engineering.