Optimization of Nozzle Diameter and Printing Speed for Enhanced Tensile Performance of FFF 3D-Printed ABS and PLA
Fused Filament Fabrication (FFF) is a widely adopted additive manufacturing technique, yet its mechanical performance is highly dependent on process parameters, particularly nozzle diameter and printing speed. This study evaluates the influence of these parameters on the tensile behavior of Acryloni...
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MDPI AG
2025-07-01
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| author | I. S. ELDeeb Ehssan Esmael Saad Ebied Mohamed Ragab Diab Mohammed Dekis Mikhail A. Petrov Abdelhameed A. Zayed Mohamed Egiza |
| author_facet | I. S. ELDeeb Ehssan Esmael Saad Ebied Mohamed Ragab Diab Mohammed Dekis Mikhail A. Petrov Abdelhameed A. Zayed Mohamed Egiza |
| author_sort | I. S. ELDeeb |
| collection | DOAJ |
| description | Fused Filament Fabrication (FFF) is a widely adopted additive manufacturing technique, yet its mechanical performance is highly dependent on process parameters, particularly nozzle diameter and printing speed. This study evaluates the influence of these parameters on the tensile behavior of Acrylonitrile Butadiene Styrene (ABS) and Polylactic Acid (PLA), aiming to determine optimal conditions for enhanced strength. ASTM D638-Type IV specimens were printed using nozzle diameters ranging from 0.05 to 0.25 mm and speeds from 15 to 80 mm/s. For ABS, tensile strength increased from 56.46 MPa to 60.74 MPa, representing a 7.6% enhancement, as nozzle diameter increased, with the best performance observed at 0.25 mm and 45 mm/s, attributed to improved melt flow and interlayer fusion. PLA exhibited a non-linear response, reaching a maximum strength of 89.59 MPa under the same conditions, marking a 22.3% enhancement over the minimum value. The superior performance of PLA was linked to optimal thermal management that enhanced crystallinity and interlayer bonding. Fractographic analysis revealed reduced porosity and smoother fracture surfaces under optimized conditions. Overall, PLA consistently outperformed ABS across all settings, with an average tensile strength advantage of 47.5%. The results underscore the need for material-specific parameter tuning in FFF and offer practical insights for optimizing mechanical performance in applications demanding high structural integrity, including biomedical, aerospace, and functional prototyping. |
| format | Article |
| id | doaj-art-61cd1e81fc8242cebf1c8412be31ef80 |
| institution | Kabale University |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-61cd1e81fc8242cebf1c8412be31ef802025-08-20T03:58:26ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-07-019722110.3390/jmmp9070221Optimization of Nozzle Diameter and Printing Speed for Enhanced Tensile Performance of FFF 3D-Printed ABS and PLAI. S. ELDeeb0Ehssan Esmael1Saad Ebied2Mohamed Ragab Diab3Mohammed Dekis4Mikhail A. Petrov5Abdelhameed A. Zayed6Mohamed Egiza7Production Engineering and Mechanical Design Department, Faculty of Engineering, Tanta University, Tanta 31527, EgyptProduction Engineering and Mechanical Design Department, Faculty of Engineering, Tanta University, Tanta 31527, EgyptProduction Engineering and Mechanical Design Department, Faculty of Engineering, Tanta University, Tanta 31527, EgyptDepartment of Mechanical Engineering, Kafrelsheikh University, Kafrelsheikh 33516, EgyptDepartment of Mechanical Engineering, Kafrelsheikh University, Kafrelsheikh 33516, EgyptDepartment of Material Forming and Additive Technologies, FSBEI HE, Moscow Polytechnic University, B. Semyonovskaya, 38, 107023 Moscow, RussiaProduction Engineering and Mechanical Design Department, Faculty of Engineering, Tanta University, Tanta 31527, EgyptDepartment of Mechanical Engineering, Kafrelsheikh University, Kafrelsheikh 33516, EgyptFused Filament Fabrication (FFF) is a widely adopted additive manufacturing technique, yet its mechanical performance is highly dependent on process parameters, particularly nozzle diameter and printing speed. This study evaluates the influence of these parameters on the tensile behavior of Acrylonitrile Butadiene Styrene (ABS) and Polylactic Acid (PLA), aiming to determine optimal conditions for enhanced strength. ASTM D638-Type IV specimens were printed using nozzle diameters ranging from 0.05 to 0.25 mm and speeds from 15 to 80 mm/s. For ABS, tensile strength increased from 56.46 MPa to 60.74 MPa, representing a 7.6% enhancement, as nozzle diameter increased, with the best performance observed at 0.25 mm and 45 mm/s, attributed to improved melt flow and interlayer fusion. PLA exhibited a non-linear response, reaching a maximum strength of 89.59 MPa under the same conditions, marking a 22.3% enhancement over the minimum value. The superior performance of PLA was linked to optimal thermal management that enhanced crystallinity and interlayer bonding. Fractographic analysis revealed reduced porosity and smoother fracture surfaces under optimized conditions. Overall, PLA consistently outperformed ABS across all settings, with an average tensile strength advantage of 47.5%. The results underscore the need for material-specific parameter tuning in FFF and offer practical insights for optimizing mechanical performance in applications demanding high structural integrity, including biomedical, aerospace, and functional prototyping.https://www.mdpi.com/2504-4494/9/7/221fused filament fabricationnozzle diameterprinting speedtensile propertiesPLA–ABS comparisonstructural integrity |
| spellingShingle | I. S. ELDeeb Ehssan Esmael Saad Ebied Mohamed Ragab Diab Mohammed Dekis Mikhail A. Petrov Abdelhameed A. Zayed Mohamed Egiza Optimization of Nozzle Diameter and Printing Speed for Enhanced Tensile Performance of FFF 3D-Printed ABS and PLA Journal of Manufacturing and Materials Processing fused filament fabrication nozzle diameter printing speed tensile properties PLA–ABS comparison structural integrity |
| title | Optimization of Nozzle Diameter and Printing Speed for Enhanced Tensile Performance of FFF 3D-Printed ABS and PLA |
| title_full | Optimization of Nozzle Diameter and Printing Speed for Enhanced Tensile Performance of FFF 3D-Printed ABS and PLA |
| title_fullStr | Optimization of Nozzle Diameter and Printing Speed for Enhanced Tensile Performance of FFF 3D-Printed ABS and PLA |
| title_full_unstemmed | Optimization of Nozzle Diameter and Printing Speed for Enhanced Tensile Performance of FFF 3D-Printed ABS and PLA |
| title_short | Optimization of Nozzle Diameter and Printing Speed for Enhanced Tensile Performance of FFF 3D-Printed ABS and PLA |
| title_sort | optimization of nozzle diameter and printing speed for enhanced tensile performance of fff 3d printed abs and pla |
| topic | fused filament fabrication nozzle diameter printing speed tensile properties PLA–ABS comparison structural integrity |
| url | https://www.mdpi.com/2504-4494/9/7/221 |
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