Optimization of 3D printing parameters for enhanced tensile properties in continuous carbon fiber reinforced PLA composites

Abstract In this study, the effect of 3D printing process parameters, specifically line width and layer thickness, on the tensile properties of continuous carbon fiber-reinforced PLA composites fabricated via the Fused Filament Fabrication (FFF) method was investigated. The incorporation of continuous carbon fibers into the PLA matrix aims to enhance the mechanical performance of the printed composites, overcoming the inherent limitations of polymer-based additive manufacturing. The Taguchi method was employed to optimize the process parameters, enabling a systematic evaluation of their influence on tensile strength. An L9 orthogonal array was used to design the experiments, and the Signal-to-Noise (S/N) ratio was analyzed to determine the optimal parameter combination. The results demonstrate that line width and layer thickness significantly affect the tensile performance of printed composites, with narrower line widths (1.0 mm) and thinner layers (0.2 mm) yielding the highest tensile strength (291.3 MPa). Statistical analysis using Analysis of Variance (ANOVA) revealed that line width contributes 58.65% to the overall mechanical performance, making it the most influential factor, followed by layer thickness (33.55%). Microstructural analyses further confirmed that optimized printing parameters improve fiber alignment, enhance interlayer bonding, and minimize void formation. These findings highlight the crucial role of process optimization in maximizing the mechanical properties of FFF-printed continuous carbon fiber reinforced polymer (CFRP) composites, offering insights into achieving high-performance and lightweight structural components.