Experimental Investigation into the Influence of Infill Density, Print Pattern, and Built-Up Direction on the Flexural Strength of FFF-Manufactured PLA Components

This study evaluates the flexural strength of poly lactic acid parts (PLAs) fabricated with fused filament fabrication (FFF) by systematically analyzing the combined effects of infill density, infill pattern, and built-up orientation. Therefore, samples with 10, 30, 50, 70, and 90% infill densities were printed with cubic and triangular patterns in all three possible built-up directions (Cartesian X, Y, Z) and subjected to a standardized three-point bending test according to ISO 178, while printing time was concurrently assessed to quantify trade-offs between mechanical performance and manufacturing efficiency. The results show that a cubic infill with layers transverse to the bending load (Y-direction) offers the highest flexural strength of about 31 MPa for 90% infill density at comparably low printing times. In addition to significantly longer printing times, samples printed in the X-direction achieved the highest flexural strengths across all configurations tested for both infill patterns examined, up to densities of approximately 60%.