Laser cutting of FDM-printed PLA/wood composites: experimental investigation and numerical modeling analysi

In recent years, laser post-processing has gained considerable attention for enhancing the dimensional accuracy of 3D-printed parts fabricated by fused deposition modeling (FDM). This study focuses on optimizing the CO2 laser cutting process for post-processing 3D-printed polylactic acid/wood (PLA-wood) composites. To comprehensive evaluation of process, laser cutting parameters (laser speed (feed rate), laser power, and the stand of distance) as well as the raster angle (printing orientation) selected as input parameters and top kerf width (TKW), bottom kerf width (BKW), heat-affected zone (the top and bottom HAZ), and ratio of the top to bottom kerf width were chosen as output parameters. Central Composite Design (CCD) from response surface methodology (RSM) was used for the design of experiments (DOE) of the model, and predict the process responses. The results demonstrate that stand of distance has maximum effects on TKW and ratio, while Laser speed has a maximum impact on BKW and Top HAZ. Increasing stand of distance, increasing laser power, and lowering laser speed effectively increase TKW and BKW. The maximum TKW (532 μm) and BKW (474 μm) were attained at the highest laser power of 84 W, the lowest laser speed of 10 mm/s, a raster angle of 0°, and the greatest stand-off distance of 7 mm. The laser power of 60 W, the laser speed of 20 mm/s, the stand of distance of 5.5 mm, and the raster angle of 90° proved to be the optimal input parameters.