Fused deposition modelling (FDM) is a popular but complex additive manufacturing process that works with many process parameters which are crucial to investigate. In this study, 3D parts were fabricated by placing each filament layer in opposite direction to the others; for this, two combinations of raster angles, (45° −45°) and (0° 90°), along with three different infill speeds were used. In this study, two 3D printing material types—Polylactic Acid (PLA) and tough-PLA were used. The material properties of each 3D part were investigated to identify the best combination of these parameters. A microstructural analysis was also performed on outer and inner surfaces along with fracture interface of the parts after tensile testing using a scanning-electron-microscopy (SEM) to explain material failure modes and reasons. The results suggest that for both the material types, a raster angle of 45° −45° produces stronger parts than to a raster angle of 0° 90°. This study also suggests that a slow infill speed improves tensile properties by providing a better inner-connection between two contiguous roasters. Thus, the detailed analysis of microstructural defects correlated with tensile test results provides insight into the optimisation of raster angle and infill speed, and scope for improvement of mechanical properties.

One of the most significant parameters of the Fused Deposition Modelling (FDM) for 3D printing process is the raster angle. In this study, the five different raster angles are used to fabricate the 3D parts using thermoplastic material -polylactic acid (PLA), and tensile properties of these parts are investigated to identify the best raster position to fabricate the strongest 3D printing part. In this study, the microstructural analyses on fracture interface, and on outer and inner surfaces of these 3D parts are performed using a scanning electron microscopy (SEM) to examine material failure modes and reasons, and defects in the 3D parts. This study identified the best raster orientation to lie down the layers of 3D printing material during the process. This study also identified that there are several defects in 3D printed parts at micro level that have large impact on mechanical properties of 3D printed part.

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