Optimising the FDM additive manufacturing process to achieve maximum tensile strength: a state-of-the-art review

Purpose Additive manufacturing or “3D printing” is a rapidly expanding sector and is moving from a prototyping service to a manufacturing service in its own right. With a significant increase in sales, fused deposition modelling (FDM) printers are now the most prevalent 3D printer on the market. The increase in commercial manufacturing necessitates an improved understanding of how to optimise the FDM printing process for various product mechanical properties. This paper aims to identify optimum print parameters for the FDM process to achieve maximum tensile strength through a review of recent studies in this field. Design/methodology/approach The effect of the governing printing parameters on the tensile strength of printed samples will be considered, including material selection, print orientation, raster angle, air gap and layer height. Findings The key findings include material recommendations, such as the use of emerging print materials like polyether-ether-ketone (PEEK), to produce samples with tensile strength over 200 per cent that of conventional materials such as acrylonitrile butadiene styrene (ABS). Amongst other parameters, it is shown that printing in the “upright” orientation should be avoided (samples can be up to 50 per cent weaker in this orientation) and air gap and raster width should be concurrently optimised to ensure good “inter-raster” bonding. The optimal choice of raster angle depends on print material; in ABS for example, selecting a 0° raster angle over a 90° angle can increase tensile strength by up to 100 per cent. Originality/value The paper conclusions provide researchers and practitioners with an up-to-date, single point reference, highlighting a series of robust recommendations to optimise the tensile strength of FDM-printed samples. Improving the mechanical performance of FDM-printed samples will support the continued growth of this technology as a viable production technique.