Multi-objective numerical optimization of 3D-printed polylactic acid bio-metamaterial based on topology, filling pattern, and infill density via fatigue lifetime and mass

Optimization of 3D printing parameters in polylactic acid bio-metamaterial under cyclic bending loading considering fracture features

3D printing has become a crucial additive manufacturing technique with the applications in various industries. Fused deposition modeling (FDM) is a common additive manufacturing process that offers considerable flexibility in the component fabrication through multiple parameters, which strongly influence the properties of the produced parts. This study focused on the impact of different printing parameters on the fatigue behavior of polylactic acid (PLA). The standard samples were 3D-printed with varying speed (5, 10, and 15 mm/s), print temperature (180, 210, and 240 °C), and nozzle diameter (0.2, 0.4, and 0.6 mm). The fatigue properties were evaluated through rotating bending fatigue tests, and a model was developed based on the results with a statistical analysis. The model accuracy was validated and the interactions between the parameters were analyzed. The optimization study found that a print speed of 5 mm/s, print temperature of 210 °C, and nozzle diameter of 0.2 mm were optimal. The fracture surfaces were also examined using a scanning electron microscopy, revealing the presence of crazing despite the brittle behavior of PLA.