Effect of 3D Printing Parameters on the Fatigue Properties of Parts Manufactured by Fused Filament Fabrication: A Review

Abstract

The advancement in 3D printing techniques has raised the hope to use additively manufactured parts as final products in various industries. However, due to the layer-by-layer nature of AM parts, they are highly susceptible to failure when they are subjected to fatigue loading. This review provides a detailed account of the influence of 3D printing parameters on the fatigue properties of parts manufactured by fused filament fabrication (FFF). Existing standards for fatigue testing of polymers and their limitation for 3D-printed parts are discussed. In addition, the cyclic behaviour of polymers is reviewed, and the impact of 3D printing parameters on the mechanical behaviour of FFF parts under tensile, compressive, flexural, and bending fatigue is investigated according to the published results in the literature. Finally, a summary of the works undertaken and suggestions for future research are provided. The influence of 3D printing parameters on the fatigue performance of prints can be different from that seen in the case of static loading and strongly depends on the fatigue loading type. While cross-over infill patterns, higher infill density, and higher layer height favour achieving higher fatigue strength in all loading types, raster orientation is best to be aligned parallel to the tensile loads and perpendicular to the compressive, flexural, and bending forces. In the case of tensile and flexural loading, Y build orientation yields the best result. Finally, print velocity was found to be less significant compared to other parameters, implying that it can be set at high values for faster printing.

Energy Consumption vs. Tensile Strength of Poly[methyl methacrylate] in Material Extrusion 3D Printing: The Impact of Six Control Settings

“…For the material extrusion (MEX) 3D printing process, research on the mechanical properties of parts built with polymers, such as Acrylonitrile Butadiene Styrene (ABS) [ 1 , 2 , 3 ], Polycarbonate (PC) [ 4 , 5 , 6 , 7 ], Polylactic Acid (PLA) [ 8 , 9 , 10 ], Polyamide 12 (PA12) [ 11 , 12 , 13 , 14 , 15 ], Thermoplastic Polyurethane (TPU) [ 16 , 17 ], polyester [ 18 ] is extensive. Polymers have been studied in the pure form [ 3 , 4 , 8 , 11 , 16 , 19 ] and as matrices in composites [ 9 , 12 , 18 ].…”

Experimental and statistical investigation on flexural properties of FDM fabricated PLA specimens applying response surface methodology

“…Another important aspect is the suitable selection of process parameters with respect to objectives involving mechanical strength, fatigue, wears, tension-compression, etc. [4][5][6]. In [4] an extensive review concerning the effect of important process parameters of fused deposition modeling are discussed.…”

“…[4][5][6]. In [4] an extensive review concerning the effect of important process parameters of fused deposition modeling are discussed. Emphasis is given to the fatigue performance of polymeric specimens fabricated using FDM.…”

Influence of 3D Printing Conditions on Some Physical–Mechanical and Technological Properties of PCL Wood-Based Polymer Parts Manufactured by FDM

“…The literature provides multiple studies that analyse the influence of printing conditions and parameters and post-processing methods on the mechanical properties of 3D-printed parts, especially FDM [ 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 ]. Several researchers have contributed with comprehensive reviews on these issues [ 12 , 13 , 14 ]. Furthermore, the subject continuously develops due to the increasing interest in different industries, requiring more attention from the scientific community.…”