Abstract:
Fused Deposition Modeling (FDM) 3D printing has become increasingly popular for producing parts that are both affordable and customizable. Among the materials commonly used in FDM, Polylactic Acid (PLA) is notable, but its mechanical performance is somewhat limited. To address these limitations, Carbon Fiber Reinforced PLA (CFRPLA) has been developed, incorporating a 15% weight fraction of carbon fiber. This study explores the effects of various critical FDM process parameters—such as raster angle, infill pattern, extruder temperature, layer thickness, and printing speed—on the mechanical properties of both PLA and CFRPLA. The findings from the experiments show that PLA offers higher strength and ductility compared to CFRPLA. However, CFRPLA demonstrates superior hardness and toughness in certain cases. Of all the parameters examined, raster angle and infill pattern were found to have the most significant impact on the tensile properties of both materials. To further investigate the materials' behavior, post-processing was performed through annealing at temperatures of 90°C, 100°C, and 120°C for durations of 3, 4, and 6 hours. The results show that annealing PLA and CFRPLA at 100°C for 4 hours optimizes strength and toughness with minimal standard deviation. CFRPLA also exhibits better thermal and dimensional stability. Further, Scanning Electron Microscopy (SEM) analysis of both the pre- and post-processed specimens highlighted microstructural changes influencing mechanical properties, while Differential Scanning Calorimetry (DSC) assessed thermal behavior and stability under heat treatment This research provides a comparative analysis of the effects of FDM process parameters and annealing on the properties of PLA and CFRPLA, offering valuable insights into the benefits and drawbacks of commercially available CFRPLA. Additionally, it demonstrates the potential of post-processing techniques in optimizing mechanical and thermal properties. By integrating mechanical testing with SEM and DSC analyses, this study contributes to a deeper understanding of material behavior, advancing FDM 3D printing in terms of material and process optimization.