Multi-Objective Optimization of FDM Printing Parameters for Enhanced Tensile Performance of Carbon Fiber-Reinforced PLA Composites

Abstract The present work attempts to determine the optimal printing conditions for enhancing tensile performance and investigates the effects of fused deposition modeling (FDM) process parameters on the tensile performance of carbon-fiber-reinforced polylactic acid (PLA-CF) composites. The influence of FDM process parameters, including layer thickness, infill ratio, raster orientation, and printing temperature, was examined using a Taguchi L9 orthogonal array design. To maximize the effect of the process on the tensile characteristics of the 3D printing composite, such as tensile strength, modulus of elasticity, and tensile toughness, a combination of the Taguchi approach and Gray Relational Analysis (GRA) was used. A layer thickness of 0.20 mm, 100% infill, 0° raster orientation, and a printing temperature of 215°C are the optimal parameters provided by both methods are the same. The optimal values for tensile strength, modulus of elasticity, and tensile toughness, respectively, were found to be 45.2 MPa, 606.943 MPa, and 175.037 MJ/m³, respectively. ANOVA revealed that infill ratio was the most influential parameter, contributing 48.68% to the overall grey relational grade, followed by layer thickness (28.81%), raster orientation (12.02%), and printing temperature (10.50%). These findings highlight the potential of PLA-CF composites for advanced structural and functional component additive manufacturing technologies as well as high-strength engineering applications.