Determining Optimal Slicer Settings for Enhanced Mechanical Performance in FDM Printing

Fused Deposition Modeling (FDM) is widely utilized for rapid prototyping and functional part production, yet the mechanical reliability of printed components remains highly dependent on slicer-defined parameters. This study began with the goal of identifying slicer settings that maximize part strength under tensile, compressive, and flexural loading. A comprehensive review of prior experimental literature was conducted, revealing that 100% infill density consistently delivers the highest strength across test types. However, the literature left unresolved a key implementation detail: the mechanical distinction between achieving 100% infill through traditional raster patterns versus increasing vertical perimeter counts. To address this gap, the present work experimentally compares both approaches using PLA+ printed on an Ankermake M5. Furthermore, the data was analyzed to convert raw failure loads into stress values, allowing for a material-level comparison of the printing strategies. Additionally, the effect of print temperature and fuzzy surface skin on interlayer adhesion was examined through tensile testing. Results confirm that higher print temperatures improve interlayer adhesion, while fuzzy skin weakens it. Critically, the vertical wall strategy is shown to be a more effective method for creating strong solid parts in bending applications, yielding higher flexural stress limits than traditional infill. These findings provide valuable insight into how slicer implementation choices affect mechanical performance and contribute practical recommendations for aerospace components where high strength-to-weight ratios are essential.