Enhancing additive manufacturing for multi-layer samples: experimental analysis of aluminum sheet thickness and perforation geometry via fused filament fabrication

The widespread integration of 3D printing technologies across diverse sectors, including prototyping and automotive industries, underscores their growing importance. This study aims to investigate the influence of aluminium sheet parameters (specifically, thickness, number, and perforation diameter) on the mechanical properties of multi-layer specimens fabricated using Fused filament fabrication (FFF) 3D printing. Polylactic acid sheets were deposited on both sides of aluminium sheets, creating a sandwich structure to enhance strength and flexibility. Aluminium sheets of varying thickness (1 mm and 2 mm) with perforations of 5 mm and 7 mm diameters were examined. Mechanical testing included flexural, compression, and impact assessments. Results from the flexural tests demonstrated that specimens reinforced with 2 mm thick aluminum sheets exhibited significantly higher force at failure. Compression testing revealed a notable increase in maximum compressive force for samples incorporating aluminium sheets. Charpy impact testing indicated an 882% improvement in impact strength for samples with a 2 mm aluminium sheet compared to those without. These findings highlight the critical role of aluminium sheet parameters in enhancing the mechanical performance of FFF-printed multi-layer structures. The study provides valuable insights for optimizing the design and fabrication of composite materials in additive manufacturing applications. The enhanced mechanical properties observed underscore the potential for these materials in sectors requiring robust and resilient components, such as aerospace and automotive industries.