Analysis and optimization of FDM process parameters for enhanced tensile strength and surface quality in PLA-metal composites

Fused Deposition Modeling (FDM), the preferred additive manufacturing technology used for creating plastic-based parts, due to its affordability and simplicity of use. A well-known material used in FDM is Polylactic acid (PLA); however, its mechanical properties limit its use as a functional part for many applications. This research investigates the effect Copper-reinforcement has on PLA material's ultimate tensile strength (UTS) during production with a FDM process. The max tensile strength measured during this study was produced using a combination of low layer thickness (0.14 mm), high infill (90%), and high printing speed (100 mm/s). The wall thickness had a point of maximum tensile strength which was found at approximately 1.2 mm before strength began to decrease. Surface finish results were achieved with a combination of 0.14 mm layer thickness, 95 mm/s printing speed, 85% infill, and 1.0 mm wall thickness, and deviations from these settings led to increased roughness due to thermal and structural factors. Multi-objective evolutionary algorithm-based optimization MOEA/D method produced a combined "knee" point for tensile strength that was greater than all the highest experimental tensile strength measures while maintaining surface roughness identical to established through experimental means, demonstrating the effectiveness of multi-objective FDM parameter optimization utilizing it.