Optimization of FDM 3D Printing Parameters for Tensile Strength of PLA-CF using Taguchi Method

Abstract

This study presents the experimental investigation and optimization of tensile strength of carbon fiber reinforced polylactic acid (CF-PLA) composites fabricated using fused deposition modeling (FDM). The influence of key process parameters, namely layer height, infill density, nozzle temperature, and print speed, was analyzed using the Taguchi L9 orthogonal array. Tensile testing was performed according to ASTM D638 standards. The experimental results showed that tensile strength varied from 23.44 MPa to 31.00 MPa. Signal-to-noise (S/N) ratio analysis indicated that infill density is the most influential parameter, followed by layer height and print speed, while nozzle temperature showed minimal effect. Analysis of variance (ANOVA) revealed that infill density contributes approximately 83.75% to tensile strength variation. The optimal parameter combination was identified as 0.1 mm layer height, 80% infill density, 220°C nozzle temperature, and 40 mm/s print speed. A regression model developed for prediction showed high accuracy with R² = 99.82%. The findings demonstrate the importance of parameter optimization in enhancing the mechanical performance of FDM-printed composite components.

Introduction

The text discusses a study on improving the tensile strength of carbon fiber-reinforced PLA (CF-PLA) materials used in Fused Deposition Modeling (FDM) 3D printing. While PLA is widely used due to its biodegradability and ease of printing, it has limitations such as brittleness and moderate strength. Reinforcing it with carbon fibers enhances mechanical properties, but performance still depends heavily on printing parameters.

The study focuses on optimizing key FDM parameters—layer height, infill density, nozzle temperature, and print speed—using the Taguchi method (L9 orthogonal array) and ANOVA analysis to reduce experiments and identify the most influential factors. Tensile testing was conducted using a Universal Testing Machine, and results were evaluated using signal-to-noise (S/N) ratios to determine optimal conditions.

Results show that tensile strength varies significantly (23.44–31.00 MPa), with the highest strength achieved at high infill density (80%) and lower print speed, indicating that infill density is the most critical factor affecting strength. Lower infill and higher speeds lead to weaker interlayer bonding and reduced mechanical performance.

Conclusion

This study presented a systematic investigation into the effects of key fused deposition modeling (FDM) process parameters—layer height, infill density, nozzle temperature, and print speed—on the tensile performance of carbon fiber reinforced polylactic acid (CF-PLA) composites. A Taguchi L9 orthogonal array was employed to design the experiments, and statistical tools including signal-to-noise (S/N) ratio analysis and analysis of variance (ANOVA) were used to quantify the influence of each parameter. The experimental results demonstrated that tensile strength varied significantly with process parameters, ranging from 23.44 MPa to 31.00 MPa. Among the factors considered, infill density was identified as the dominant parameter, contributing approximately 83.75% to the overall variation in tensile strength. Layer height and print speed exhibited moderate influence, whereas nozzle temperature showed comparatively limited impact within the selected parameter range. The optimal parameter combination for maximizing tensile strength was determined to be 0.1 mm layer height, 80% infill density, 220°C nozzle temperature, and 40 mm/s print speed. Furthermore, the developed regression model exhibited strong predictive capability, with a coefficient of determination (R²) of 99.82%, indicating excellent agreement between experimental and predicted values. The analysis also revealed that higher infill densities enhance stiffness and tensile strength, while lower infill densities improve ductility, highlighting an inherent trade-off between strength and elongation characteristics. In conclusion, the findings confirm that precise optimization of FDM process parameters plays a critical role in enhancing the mechanical performance of CF-PLA components. This study provides a reliable framework for parameter selection and process optimization, contributing to the development of high-performance, lightweight additively manufactured parts for engineering applications such as automotive and aerospace sectors.

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Copyright

Copyright © 2026 Rahul K, Kishore P, K Velmurugan. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.