Investigation of mechanical properties in FFF- produced PLA samples using the Erichsen test: application of definitive screening and RSM

Purpose This study aims to investigate how printing parameters affect the mechanical properties of specimens produced through fused filament fabrication, using the Erichsen test to assess deformation characteristics and material durability under stress. Design/methodology/approach Polylactic acid (PLA) specimens were printed and tested in accordance with the ISO 20482 standard. Definitive screening was conducted to identify the most influential process parameters. This study examined the effects of four key process parameters – number of layers, layer height, crossing angle and nozzle diameter – on force, distension, peak energy and energy to break. Each parameter was assessed at three levels and a large number of required experiments was managed by using response surface methodology (RSM). Findings This study revealed that the number of layers, layer height and crossing angle are the most significant factors that influence the mechanical properties of 3D-printed materials. The number of layers had the greatest impact on the peak force, contributing 44.25%, with thicker layers typically enhancing material strength. The layer height has a significant effect on energy absorption and deformation, with greater layer heights generally improving these properties. Nozzle diameter contributed only 1.10%, making it the least influential factor; however, its impact became more pronounced in interactions with other parameters. Originality/value This paper presents a comprehensive experimental investigation into the effects of process parameters on the crack strength and behavior of 3D-printed PLA specimens using the RSM method. The documented results can be used to develop optimization models aimed at achieving desired mechanical properties with reduced variation and uncertainty in the final product.