Experimental Investigation of Process Parameters on Surface and Mechanical Performance of 3D Printed Parts

Abstract This study examines the influence of print orientation and printing speed on the mechanical strength and surface roughness of components fabricated from Polylactic Acid (PLA) using the Fused Deposition Modeling (FDM) process. The 3D-printed samples were produced with varying orientations (0°, 90°, and 45°) and print speeds, while other parameters remained constant. All samples had a 100% infill density, a “Lines” infill pattern, and a printing temperature of 210°C. The 0° and 90° samples were printed at 50 mm/s, whereas the 45° samples were printed at 40, 60 and 80 mm/s. Each sample was printed three times to ensure repeatability and obtain an average result. The results indicate that raster angle plays a critical role in determining mechanical performance, with 0° and 90° orientations yielding the highest 72.31 MPa and lowest 56.26 MPa stress values, respectively. Additionally, a nuanced relationship was observed between printing speed, surface roughness, and tensile strength. Surface roughness metrics, including Ra, Rz, and Rq, improved with decreasing printing speed, indicating enhanced surface finishes. The optimal tensile strength of 57.95 MPa was achieved at a moderate printing speed of 60 mm/s, offering the best balance between mechanical strength and surface quality. This research enhances the understanding of parameter optimisation in FDM processes, providing practical insights for the production of high-performance PLA-based components.