Optimization of FDM Process Parameters through Experimental and Numerical Investigation of the Tensile and Flexural Behavior of Polylactic Acid (PLA) Specimens.

Abstract

Additive Manufacturing using Fused Deposition Modeling (FDM) has emerged as a widely adopted technology for producing complex components with reduced material waste, shorter production cycles, and enhanced design flexibility. Among the materials used in FDM, Polylactic Acid (PLA) is one of the most popular biodegradable thermoplastics due to its ease of processing, environmental sustainability, and favourable mechanical properties. This Research presents an integrated experimental and numerical investigation of the tensile and flexural behavior of FDM-printed PLA specimens, with a focus on process parameter optimization. Key FDM process parameters, including layer thickness, infill density, Print Speed and Nozzle Temperature were systematically varied to evaluate their influence on the mechanical performance of the printed Specimens and to identify optimal printing conditions. Standard Tensile test specimens (Dog-bone Shape, ASTM D638 Type V) and Flexural Test specimens (Rectangular bar shape, ASTM D790) were designed and printed by using FDM. Mechanical characterization was carried out using a Universal Testing Machine (UTM) to determine tensile strength, flexural strength, flexural modulus, deformation characteristics, and load–deflection behavior. In parallel, Finite Element Analysis (FEA) was performed using ANSYS Workbench to simulate the experimental loading conditions and predict stress distribution, strain response, and deformation behavior. The numerical model incorporated the effects of print-induced anisotropy and interlayer bonding to improve the accuracy of the simulations. The experimental results were compared with numerical predictions to validate the finite element model and assess its capability to represent the mechanical behavior of FDM-printed PLA specimens. A good correlation was observed between the experimental and simulation results, with minor deviations attributed to manufacturing imperfections and material variability inherent to the FDM process. Based on the combined experimental and numerical findings, optimal process parameter settings were identified to enhance tensile and flexural performance. The study demonstrates the effectiveness of integrating experimental testing, numerical simulation, and process parameter optimization for improving the structural reliability and mechanical performance of biodegradable PLA components manufactured through FDM.