Influence of FDM Processing Parameters on the AC Breakdown Strength of Oil-Immersed PLA Insulation

This study presents an experimental investigation of 3D-printed poly(lactic acid) samples (PLA) subjected to high-voltage AC stress. Although additive manufacturing is gaining importance in electrical engineering, studies on FDM-printed materials have concentrated mainly on mechanical behaviour. Their dielectric strength under oil-immersed high-voltage stress—a critical aspect for insulation applications—has not been systematically investigated. Additive manufacturing is increasingly considered for auxiliary insulating components in oil-immersed high-voltage equipment; however, process-induced voids and interlayer interfaces can intensify the local electric field and reduce dielectric strength. This work evaluates the AC breakdown strength of 3D-printed PLA specimens under oil immersion using the standard AC electrical strength test method for solid insulating materials. Two parameter sets were investigated: extrusion temperature (190–240 °C ) at a constant nozzle diameter, and nozzle diameter (0.3–0.6 mm) at a constant extrusion temperature of Te=200°C. Breakdown data were analysed using the standard two-parameter Weibull approach typically used in the statistical evaluation of electrical insulation breakdown strength, with the results additionally expressed in terms of the B10, B50, and B90 percentiles. The experimental observations were interpreted using simplified electric-field simulations representing inter-bead and interlayer voids. The results indicate that, for a given material, there exists an optimal extrusion temperature that yields the highest electrical breakdown performance.