FDM Fabrication and Process Parameters Optimization for Thermoplastic Polymer Blend with Nanoparticles

Abstract

newline Fused deposition modelling (FDM) has recently emerged as a prominent additive manufacturing technology. Polymer composites are emerging that may be suitable for fabrication of real time applications product through 3D printing, obviating the need for the subtractive manufacturing steps associated with the traditional workflow. This study presents a systematic study on the development of high-performance Polylactic Acid-Nano Graphene (PLA-nGr) composites for real time applications using FDM technology. Following that, the reinforcements were added at varying weight proportions of 1.5%, 3%, 4.5%, and 6% nano Graphene by weight to PLA respectively. Melt Flow Index and Differential Scanning Calorimetric test has been used for finalizing the composition of reinforcement. 4.5 wt% Nano Graphene reinforced PLA is found to be more thermally stable than other PLA compositions (1.5%, 3%, and 6% nano Graphene by weight to PLA) based on the findings of crystallinity and endothermic enthalpy. After finalizing the composition, filament has been fabricated using EVO felfill extruder. Further study focuses on methodically varying FDM process parameters including nozzle temperature, infill pattern and infill density. Three samples of each composition (PLA + 4.5% Nano Graphene) for different levels of three different processing parameters, Extrusion temperature, Infill pattern and Infill density have been printed for Tensile test, Impact Strength, Wear rate, Compressive strength and Surface Roughness as per ASTM standard. The findings indicate that the FDM process parameters significantly affect the quality and performance of the manufactured components. The study s proposed approach and analytical tools are broadly applicable and will be utilised across various AM technologies, especially for nonlinear systems with multiple inputs and the management of numerous interdependent outputs.