Skip to main content

Advertisement

SpringerLink
Log in

Parameter optimization for PETG/ABS bilayer tensile specimens in material extrusion 3D printing through orthogonal method

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Fused deposition modeling is a rapidly evolving manufacturing technique that can produce products with complex geometries in minimum waste. However, the limited material selections and poor quality in the products from this technique restrict its applications. Many researchers have found some parameters affecting single-material specimen mechanical properties, layer thickness, infill density, and printing speed. However, few manufacturing parameter studies have examined dual-material products. This study used acrylonitrile butadiene styrene and polyethylene-terephthalate-glycol to fabricate dual-material samples because of their characteristics. All samples were first fabricated half-thickness acrylonitrile butadiene styrene base with polyethylene-terephthalate-glycol part fabricated onto, since the functionalities from both can be obtained from this configuration. Sixteen batches were produced in relation to printing speed, layer thickness, and infill density using the orthogonal method, followed by parameter optimization and a verification test. The batch with the parameters of 30 mm/s printing speed, 0.1 mm layer thickness, and 75% infill density produced the best combination for samples (the highest tensile strength (44.73 MPa) and Young’s modulus (758.12 MPa)). This run finished fabrication in 113 min, faster than run 9 in the orthogonal method, which had the highest tensile performance of the 16 runs. The morphologies agreed the results and found a lower layer thickness increased layers in fabrication with less pores and voids. This research on FDM-produced multi-material specimens’ mechanical properties increases the likelihood that this technique will be used in future manufacturing.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6

Similar content being viewed by others

References

  1. Tymrak BM, Kreiger M, Pearce JM (2014) Mechanical properties of components fabricated with open-source 3-D printers under realistic environmental conditions. Mater Des 58:242–246. https://doi.org/10.1016/j.matdes.2014.02.038

    Article  Google Scholar 

  2. Sugavaneswaran M, Arumaikkannu G (2015) Analytical and experimental investigation on elastic modulus of reinforced additive manufactured structure. Mater Des 66:29–36. https://doi.org/10.1016/j.matdes.2014.10.029

    Article  Google Scholar 

  3. Domingo-Espin M, Puigoriol-Forcada JM, Garcia-Granada AA, Llumà J, Borros S, Reyes G (2015) Mechanical property characterization and simulation of fused deposition modeling Polycarbonate parts. Mater Des 83:670–677. https://doi.org/10.1016/j.matdes.2015.06.074

    Article  Google Scholar 

  4. Casavola C, Cazzato A, Moramarco V, Pappalettere C (2016) Orthotropic mechanical properties of fused deposition modelling parts described by classical laminate theory. Mater Des 90:453–458. https://doi.org/10.1016/j.matdes.2015.11.009

    Article  Google Scholar 

  5. Gong K, Liu H, Huang C, Cao Z, Fuenmayor E, Major I (2022) Hybrid manufacturing of acrylonitrile butadiene styrene (ABS) via the combination of material extrusion additive manufacturing and injection molding. Polymers 14(23):5093. https://doi.org/10.3390/polym14235093

  6. Solomon IJ, Sevvel P, Gunasekaran J (2020) A review on the various processing parameters in FDM. Mater Today: Proc:509–514. https://doi.org/10.1016/j.matpr.2020.05.484

  7. Xu H, Ebrahimi F, Gong K, Cao Z, Fuenmayor E, Major I (2023) Hybrid manufacturing of oral solid dosage forms via overprinting of injection-molded tablet substrates. Pharmaceutics 15(2):507. https://doi.org/10.3390/pharmaceutics15020507

    Article  Google Scholar 

  8. Dawoud M, Taha I, Ebeid SJ (2016) Mechanical behaviour of ABS: an experimental study using FDM and injection moulding techniques. J Manuf Process 21:39–45. https://doi.org/10.1016/j.jmapro.2015.11.002

    Article  Google Scholar 

  9. Chohan JS, Singh R (2016) Enhancing dimensional accuracy of FDM based biomedical implant replicas by statistically controlled vapor smoothing process. Progress in Additive Manufacturing 1(1-2):105–113. https://doi.org/10.1007/s40964-016-0009-4

    Article  Google Scholar 

  10. Nabavi-Kivi A, Ayatollahi MR, Rezaeian P, Razavi SMJ (2021) Investigating the effect of printing speed and mode mixity on the fracture behavior of FDM-ABS specimens. Theoretical and Applied Fracture Mechanics 118:103223. https://doi.org/10.1016/j.tafmec.2021.103223

    Article  Google Scholar 

  11. Aquino RP, Barile S, Grasso A, Saviano M (2018) Envisioning smart and sustainable healthcare: 3D printing technologies for personalized medication. Futures 103:35–50. https://doi.org/10.1016/j.futures.2018.03.002

    Article  Google Scholar 

  12. Fuenmayor E et al (2019) Mass-customization of oral tablets via the combination of 3D printing and injection molding. Int J Pharm 569:118611. https://doi.org/10.1016/j.ijpharm.2019.118611

    Article  Google Scholar 

  13. Araújo MRP, Sa-Barreto LL, Gratieri T, Gelfuso GM, Cunha-Filho M (2019) The digital pharmacies era: how 3D printing technology using fused deposition modeling can become a reality. Pharmaceutics 11(3). https://doi.org/10.3390/pharmaceutics11030128

  14. Rigotti D, Dorigato A, Pegoretti A (2018) 3D printable thermoplastic polyurethane blends with thermal energy storage/release capabilities. Mater Today Commun 15:228–235. https://doi.org/10.1016/j.mtcomm.2018.03.009

    Article  Google Scholar 

  15. Liu Y, Liang X, Saeed A, Lan W, Qin W (2019) Properties of 3D printed dough and optimization of printing parameters. Innov Food Sci Emerg Technol 54:9–18. https://doi.org/10.1016/j.ifset.2019.03.008

    Article  Google Scholar 

  16. Barile G, Esposito P, Stornelli V, Ferri G (2023) Development and analysis of a multimaterial FDM 3D printed capacitive accelerometer. IEEE Access:1. https://doi.org/10.1109/ACCESS.2023.3246731

  17. Quero RF, de Castro Costa BM, da Silva JAF, de Jesus DP (2022) Using multi-material fused deposition modeling (FDM) for one-step 3D printing of microfluidic capillary electrophoresis with integrated electrodes for capacitively coupled contactless conductivity detection. Sens Actuators B 365:131959. https://doi.org/10.1016/j.snb.2022.131959

    Article  Google Scholar 

  18. Han D, Lee H (2020) Recent advances in multi-material additive manufacturing: methods and applications. Curr Opin Chem Eng 28:158–166. https://doi.org/10.1016/j.coche.2020.03.004

    Article  Google Scholar 

  19. Gebisa AW, Lemu HG (2019) Influence of 3D printing FDM process parameters on tensile property of ultem 9085. Procedia Manuf 30:331–338. https://doi.org/10.1016/j.promfg.2019.02.047

    Article  Google Scholar 

  20. Singh R, Bedi P, Fraternali F, Ahuja IPS (2016) Effect of single particle size, double particle size and triple particle size Al 2 O 3 in Nylon-6 matrix on mechanical properties of feed stock filament for FDM. Compos Part B Eng 106:20–27. https://doi.org/10.1016/j.compositesb.2016.08.039

    Article  Google Scholar 

  21. Pham DT, Gault RS (1998) A comparison of rapid prototyping technologies

    Book  Google Scholar 

  22. Gong K et al (2022) Mass customization of polylactic acid (PLA) parts via a hybrid manufacturing process. Polymers 14(24):5413. https://doi.org/10.3390/polym14245413

    Article  Google Scholar 

  23. Gong K, Xu H, Liu H, Cao Z, Fuenmayor E, Major I (2023) Hybrid manufacturing of mixed-material bilayer parts via injection molding and material extrusion three-dimensional printing. J Appl Polym Sci. https://doi.org/10.1002/app.53972

  24. Rodríguez-Panes A, Claver J, Camacho AM (2018) The influence of manufacturing parameters on the mechanical behaviour of PLA and ABS pieces manufactured by FDM: a comparative analysis. Materials 11(8). https://doi.org/10.3390/ma11081333

  25. Durgun I, Ertan R (2014) Experimental investigation of FDM process for improvement of mechanical properties and production cost. Rapid Prototyp J 20(3):228–235. https://doi.org/10.1108/RPJ-10-2012-0091

    Article  Google Scholar 

  26. Popescu D, Zapciu A, Amza C, Baciu F, Marinescu R (2018) FDM process parameters influence over the mechanical properties of polymer specimens: a review. Polym Test 69:157–166. https://doi.org/10.1016/j.polymertesting.2018.05.020

    Article  Google Scholar 

  27. Deng X, Zeng Z, Peng B, Yan S, Ke W (2018) Mechanical properties optimization of poly-ether-ether-ketone via fused deposition modeling. Materials 11(2). https://doi.org/10.3390/ma11020216

  28. Sikder P, Challa BT, Gummadi SK (2022) A comprehensive analysis on the processing-structure-property relationships of FDM-based 3-D printed polyetheretherketone (PEEK) structures. Materialia 22:101427. https://doi.org/10.1016/j.mtla.2022.101427

    Article  Google Scholar 

  29. Chacón JM, Caminero MA, García-Plaza E, Núñez PJ (2017) Additive manufacturing of PLA structures using fused deposition modelling: effect of process parameters on mechanical properties and their optimal selection. Mater Des 124:143–157. https://doi.org/10.1016/j.matdes.2017.03.065

    Article  Google Scholar 

  30. Lokesh N, Praveena BA, Sudheer Reddy J, Vasu VK, Vijaykumar S (2021) Evaluation on effect of printing process parameter through Taguchi approach on mechanical properties of 3D printed PLA specimens using FDM at constant printing temperature. Mater Today Proc. https://doi.org/10.1016/j.matpr.2021.11.054

  31. Torrado AR, Roberson DA (2016) Failure analysis and anisotropy evaluation of 3D-printed tensile test specimens of different geometries and print raster patterns. JFAP 16(1):154–164. https://doi.org/10.1007/s11668-016-0067-4

    Article  Google Scholar 

  32. Durgashyam K, Indra Reddy M, Balakrishna A, Satyanarayana K (2019) Experimental investigation on mechanical properties of PETG material processed by fused deposition modeling method. Mater Today Proc 18:2052–2059. https://doi.org/10.1016/j.matpr.2019.06.082

    Article  Google Scholar 

  33. Wang H, Yang W, Jiao Z, Chi B, Yan H (2018) Effects of filling ratio in FDM technology on the mechanical properties of plastic products. Plastics 47(01):92–94,112

    Google Scholar 

  34. Rodríguez JF, Thomas JP, Renaud JE (2001) Mechanical behavior of acrylonitrile butadiene styrene (ABS) fused deposition materials. Experimental investigation. Rapid Prototyp J 7(3):148–158. https://doi.org/10.1108/13552540110395547

    Article  Google Scholar 

  35. Ziemian C, Sharma M, Ziemian S (2012) Anisotropic mechanical properties of ABS parts fabricated by fused deposition modelling. In: Mech Eng p 159

  36. Masood S, Mau K, Song W (2010) Tensile properties of processed FDM polycarbonate material. Mater Sci Forum 654–656:2556–2559. https://doi.org/10.4028/www.scientific.net/MSF.654-656.2556

    Article  Google Scholar 

  37. Wang CC, Lin TW, Hu SS (2007) Optimizing the rapid prototyping process by integrating the Taguchi method with the Gray relational analysis. Rapid Prototyp J 13(5):304–315. https://doi.org/10.1108/13552540710824814

    Article  Google Scholar 

  38. Anitha R, Arunachalam S, Radhakrishnan P (2001) Critical parameters influencing the quality of prototypes in fused deposition modelling. J Mater Process Technol 118(1-3):385–388. https://doi.org/10.1016/S0924-0136(01)00980-3

    Article  Google Scholar 

  39. Yin J, Lu C, Fu J, Huang Y, Zheng Y (2018) Interfacial bonding during multi-material fused deposition modeling (FDM) process due to inter-molecular diffusion. Mater Des 150:104–112. https://doi.org/10.1016/j.matdes.2018.04.029

    Article  Google Scholar 

  40. Szust A, Adamski G (2022) Using thermal annealing and salt remelting to increase tensile properties of 3D FDM prints. Eng Fail Anal 132:105932. https://doi.org/10.1016/j.engfailanal.2021.105932

    Article  Google Scholar 

  41. Fountas NA, Papantoniou I, Kechagias JD, Manolakos DE, Vaxevanidis NM (2022) Modeling and optimization of flexural properties of FDM-processed PET-G specimens using RSM and GWO algorithm. Eng Fail Anal 138. https://doi.org/10.1016/j.engfailanal.2022.106340

  42. Fuenmayor E et al (2018) Material considerations for fused-filament fabrication of solid dosage forms. Pharmaceutics 10(2):1–27. https://doi.org/10.3390/pharmaceutics10020044

    Article  Google Scholar 

  43. Rodríguez JF, Thomas JP, Renaud JE (2003) Design of fused-deposition ABS components for stiffness and strength. Journal of Mechanical Design, Transactions of the ASME 125(3):545–551. https://doi.org/10.1115/1.1582499

    Article  Google Scholar 

  44. Lay M, Thajudin NLN, Hamid ZAA, Rusli A, Abdullah MK, Shuib RK (2019) Comparison of physical and mechanical properties of PLA, ABS and nylon 6 fabricated using fused deposition modeling and injection molding. Compos Part B Eng 176:107341. https://doi.org/10.1016/j.compositesb.2019.107341

    Article  Google Scholar 

  45. Christiyan KGJ, Chandrasekhar U, Venkateswarlu K (2016) A study on the influence of process parameters on the mechanical properties of 3D printed ABS composite. IOP Conf Ser Mater Sci Eng 114(1). https://doi.org/10.1088/1757-899X/114/1/012109

  46. Cao Z, Daly M, Geever LM, Major I, Higginbotham CL, Devine DM (2016) Synthesis and characterization of high density polyethylene/peat ash composites. Compos Part B Eng 94:312–321. https://doi.org/10.1016/j.compositesb.2016.03.009

    Article  Google Scholar 

  47. Torrado AR, Shemelya CM, English JD, Lin Y, Wicker RB, Roberson DA (2015) Characterizing the effect of additives to ABS on the mechanical property anisotropy of specimens fabricated by material extrusion 3D printing. Addit Manuf 6:16–29. https://doi.org/10.1016/j.addma.2015.02.001

    Article  Google Scholar 

  48. Ebel E, Sinnemann T (2014) Fabrication of FDM 3D objects with ABS and PLA and determination of their mechanical properties. RTejournal https://www.rtejournal.de/ausgabe11/3872

  49. Baich L, Manogharan G, Marie H (2015) Study of infill print design on production cost-time of 3D printed ABS parts. Int J Rapid Manuf 5(3-4):308. https://doi.org/10.1504/ijrapidm.2015.074809

    Article  Google Scholar 

Download references

Author information

Author notes

  1. Zhixin Chen and Ke Gong have contributed equally to this work and share first authorship.

Authors and Affiliations

  1. East China University of Technology, Nanchang, 330013, Jiangxi, China

    Zhixin Chen & Cheng Huang

  2. PRISM Research Institute, Technological University of Shannon: Midlands and Midwest, Athlone Campus, N37 HD68, University Road, Athlone, Westmeath, Ireland

    Ke Gong, Han Xu, Evert Fuenmayor, Zhi Cao & Ian Major

  3. Business School, University of Leeds, Leeds, Yorkshire, LS2 8AF, UK

    Sihan Hu

Authors
  1. Zhixin Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ke Gong
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Cheng Huang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Sihan Hu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Han Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Evert Fuenmayor
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Zhi Cao
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Ian Major
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All authors contributed to the study conception and design. Material preparation was performed by Zhixin Chen, Ke Gong, Cheng Huang, Sihan Hu, Evert Fuenmayor, and Ian Major; data collection was performed by Zhixin Chen, Ke Gong, Cheng Huang, and Zhi Cao; analysis was performed by Zhixin Chen, Ke Gong, Cheng Huang, and Han Xu. The first draft of the manuscript was written by Zhixin Chen, Ke Gong, Cheng Huang, and Ian Major. All authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

Corresponding author

Correspondence to Ian Major.

Ethics declarations

Competing interests

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Chen, Z., Gong, K., Huang, C. et al. Parameter optimization for PETG/ABS bilayer tensile specimens in material extrusion 3D printing through orthogonal method. Int J Adv Manuf Technol 127, 447–458 (2023). https://doi.org/10.1007/s00170-023-11515-w

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-11515-w

Keywords

Search

Navigation