Abstract
Fused Deposition Modeling (FDM) 3D printing creates components by layering extruded material. Printer parameters such as layer height and infill density can greatly impact the mechanical properties and quality of the printed parts. One critical factor to be considered in analysis is the anisotropy nature of printed components, considering all cross-sectional area (CSA) profiles for less than 100% infill density. This paper investigates the effect of the anisotropy nature of 3D printed CSA has on stress calculations and hence mechanical properties of the specimen through Design of Experiment (DOE). Analysis of variance (ANOVA) is utilised to evaluate the results. Printed specimens were tensile tested as per ASTM D638-14. Raw data was analysed using various CSA profiles, taking changes in infill density and layer height into account. Fixed parameter such as shell count, top and bottom layers, nozzle diameter, Hexagonal pattern were defined. Specimens Ultimate Tensile Strength (UTS) values increased on average by 30% using average profile CSA data compared to using external specimen dimensions. Further analysis assessing printer parameters affect on recycled Polyethylene Terephthalate (rPET) specimen's Young's Modulus (YM) and UTS was studied. One significant finding from this study suggests that the thickness of each layer has the most significant impact on the material properties of 3D printed rPET, as observed through the analysis of tensile test data obtained from 3D printed samples. A 3D printed rPET specimen with 30% infill density and 0.25 mm layer height has a higher YM (1175 MPa) and UTS (39 MPa) compared to a specimen with 75% infill density and 0.1 mm layer height (1159 MPa, 31 MPa). However careful interpretation of the results is required because for the same 30% infill parameter at 0.2 mm layer height the YM (936 MPa) and UTM (28 MPa) are significantly lower than at 0.25 mm layer height. If a higher value of YM and UTS is required an infill setting of 50% and layer height of 0.25 mm gave the highest values, YM (1330 MPa) and UTS (43 MPa).