Short answer

To achieve predictable mechanical performance in 3D printed polymer parts, carefully control and document printing parameters, and design with the inherent anisotropy of the manufacturing process in mind.

Field: Final Production
Source: Critical reviews in solid state and materials sciences/CRC critical reviews in solid state and materials sciences (2019)
Method: Literature Review and Data Consolidation
Evidence: Strong effect

Understanding the relationship between material extrusion process parameters, resulting material structure, and final mechanical properties is crucial for predictable and reliable polymer additive manufacturing. This final production research insight is drawn from a 2019 study published in Critical reviews in solid state and materials sciences/CRC critical reviews in solid state and materials sciences. Using Literature review and data consolidation, researchers explored how this design variable affects real-world outcomes. The key design takeaway: To achieve predictable mechanical performance in 3D printed polymer parts, carefully control and document printing parameters, and design with the inherent anisotropy of the manufacturing process in mind.

Study

Final ProductionHigh ImpactStrong effect

Optimizing Polymer 3D Print Properties through Process Parameter Control

Critical reviews in solid state and materials sciences/CRC critical reviews in solid state and materials sciences · 2019

Key Findings

01Printing parameters like raster angle, infill density, and specimen orientation significantly affect the mechanical properties of 3D printed polymers.
02Anisotropy in mechanical properties is a common issue in material extrusion, often linked to texture, microstructural changes, and printing defects.
03A comprehensive database of mechanical properties for various polymers used in FFF can be compiled from existing research.

Application

Design takeaway

How to apply

When designing a functional part using material extrusion 3D printing, consult material datasheets and research specific to the chosen polymer and printer to understand how parameters like layer height, infill percentage, and print orientation affect strength. Conduct test prints to validate performance before committing to final production.

Project actions

01When designing a 3D printed object, think about which way it will be stressed and orient the print accordingly.
02If you need a strong part, consider using higher infill percentages and specific raster angles, but be aware this might increase print time and material use.

Method & Evidence

AimHow do material extrusion process parameters (e.g., raster angle, infill, specimen orientation) influence the mechanical properties (tensile, compressive, flexural, interlayer, fatigue, creep) of additively manufactured polymers?

MethodLiterature Review and Data Consolidation

ProcedureThe study systematically reviewed existing literature on polymer additive manufacturing using material extrusion (like FFF), compiling and analyzing data on mechanical properties. It examined the impact of printing parameters and identified underlying causes for property variations, such as microstructural changes and defects.

ContextPolymer Additive Manufacturing (Material Extrusion / FFF)

Variables

IV["Raster angle","Infill density","Specimen orientation"]

DV["Tensile strength","Compressive strength","Flexural strength","Interlayer strength","Fatigue properties","Creep properties"]

CV["Polymer material type","Filament diameter","Printing temperature","Print speed","Layer height","Ambient temperature and humidity"]

Strengths & Limitations

Strengths

+Comprehensive review of a wide range of mechanical properties.
+Detailed discussion of the influence of key printing parameters.
+Identification of anisotropy and its causes.

Limitations

The mechanical properties of 3D printed parts can be highly dependent on the specific printer model, filament brand, and environmental conditions, which may not be fully captured in general reviews.

Reliability & validity

The reliability of findings from individual studies reviewed can vary. Validity is strengthened by the synthesis of multiple studies, but the inherent variability in 3D printing processes can limit the generalizability of specific quantitative results.

Think critically

Given the significant impact of printing parameters on mechanical properties, how can designers develop robust design methodologies that account for potential variations in 3D printing processes and ensure consistent product performance across different machines and environments?

Design Principles

"Process parameters in additive manufacturing directly dictate material structure and, consequently, final product performance."

Designers and engineers can leverage this knowledge to select appropriate materials and printing settings to achieve desired performance characteristics in 3D printed components. This allows for the creation of functional parts with tailored mechanical strengths, stiffness, and durability, moving beyond purely aesthetic applications.

What This Means for Your Design

How you 3D print a plastic part changes how strong it is. The direction of the print lines, how much material is inside, and the angle of the print head all matter.

How to use in your project

1.Reference this study when discussing how printing parameters affect the mechanical properties of your prototype or final design.
2.Use the findings to justify your choices for print settings and material orientation in your design project.

Add to My Project

Quick Cite

Paragraph starter

The mechanical performance of additively manufactured polymer components is significantly influenced by the material extrusion process parameters. Research indicates that factors such as raster angle, infill strategy, and specimen orientation can lead to anisotropic properties, affecting tensile, flexural, and interlayer strengths. Understanding these relationships is critical for designing functional parts that meet specific performance requirements.

Source

Critical reviews in solid state and materials sciences/CRC critical reviews in solid state and materials sciences

Process–Structure–Properties in Polymer Additive Manufacturing via Material Extrusion: A Review

journal · 2019

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Questions About This Research

What does the research say about optimizing polymer 3d print properties through process parameter control?: To achieve predictable mechanical performance in 3D printed polymer parts, carefully control and document printing parameters, and design with the inherent anisotropy of the manufacturing process in mind. Evidence: Critical reviews in solid state and materials sciences/CRC critical reviews in solid state and materials sciences (2019).
Why does "Optimizing Polymer 3D Print Properties through Process Parameter Control" matter for design?: Designers and engineers can leverage this knowledge to select appropriate materials and printing settings to achieve desired performance characteristics in 3D printed components. This allows for the creation of functional parts with tailored mechanical strengths, stiffness, and durability, moving beyond purely aesthetic applications.
How can designers apply this research?: To achieve predictable mechanical performance in 3D printed polymer parts, carefully control and document printing parameters, and design with the inherent anisotropy of the manufacturing process in mind.
What were the main findings?: Printing parameters like raster angle, infill density, and specimen orientation significantly affect the mechanical properties of 3D printed polymers.. Anisotropy in mechanical properties is a common issue in material extrusion, often linked to texture, microstructural changes, and printing defects.. A comprehensive database of mechanical properties for various polymers used in FFF can be compiled from existing research.
What research method was used?: Literature Review and Data Consolidation.
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2019 journal from Critical reviews in solid state and materials sciences/CRC critical reviews in solid state and materials sciences.
What should I do differently in my next project?: When designing a functional part using material extrusion 3D printing, consult material datasheets and research specific to the chosen polymer and printer to understand how parameters like layer height, infill percentage, and print orientation affect strength. Conduct test prints to validate performance before committing to final production.
What are the limitations?: The review's findings are based on existing literature, which may have variations in experimental setups and reporting standards. Specific material behaviors can differ significantly between polymer types and even batches.