Hybrid Layer Thickness Configurations for Enhanced Mechanical Performance and Energy Efficiency FDM-Printed PLA

This study examines the impact of hybrid layer thickness configurations on the mechanical properties and energy consumption of 3D-printed polylactic acid (PLA) parts produced via Fused Deposition Modeling (FDM). PLA specimens with various combinations of outer and core layer thicknesses (0.08 mm, 0.16 mm, and 0.28 mm) were fabricated and tested for tensile strength, flexural strength, and flexural modulus, alongside measurements of energy consumption. The results revealed that hybrid structures incorporating 0.16 mm face layers and 0.08 mm core layers exhibited superior mechanical performance. In contrast, thicker core layers (0.28 mm) significantly reduced printing time and energy use. The highest tensile strength (53.57 MPa), flexural strength (90.68 MPa), and flexural modulus (2898.4 MPa) were obtained in the sample group of 0.16_0.08_0.16 mm layer thickness. Scanning Electron Microscopy (SEM) provided microstructural insights supporting these findings. The porosity and higher nozzle temperature may influence the material strength for thicker and thinner layer thicknesses, respectively. The sample group with the least energy consumption was 0.28 mm, followed by the sample group with the same layer thickness in both the face and core layers. The study highlights the potential of hybrid layering strategies to optimize performance-energy trade-offs in FDM printing, offering valuable guidance for material-efficient and functionally robust additive manufacturing.