Experimental Investigation of Fused Deposition Modelling 3D Printing Process on Propeller Blade Roughness Using PLA+

The manufacturing process now emphasizes producing high-quality products. Additive manufacturing, particularly Fused Deposition Modeling (FDM), fulfills these demands by enabling precise fabrication through filament layer extrusion. This study investigates the effects of process parameters, specifically layer thickness and infill density, on the surface roughness of PLA+ polymer material using FDM. Surface orientation plays a crucial role in determining the quality of printed components, such as propeller blades with complex geometries. Surface roughness was analyzed using the Gaussian Filter method with cutoffs of 800 µm and 25 µm at different surface points, namely top and bottom. The results indicate that layer thickness significantly impacts surface roughness. A layer thickness of 0.1 mm yielded smoother surfaces compared to 0.3 mm, as the smaller layer height reduces the formation of uneven surface lines and roughness. The higher layer thickness (0.3 mm) increased the distance between layers, resulting in a rougher texture. In conclusion, optimizing layer thickness, particularly at 0.1 mm, improves surface quality. These findings highlight the importance of parameter control in achieving high-quality 3D printed components, especially for intricate geometries like propeller blades.