A Comprehensive Review on the Optimization of the Fused Deposition Modeling Process Parameter for Better Tensile Strength of PLA-Printed Parts

Table 1

Summary of review of earlier (2020 and above) works of literature.

Material/s	Process parameter considered	Method/technique considered	Mechanical properties considered	Analysis/results	References
PLA, ABS, CFR-PLA, CFR-ABS, CNT-ABS	Infill density, infill pattern, print speed, and print temperature	DSC^a, SEM^b, TGA^c	Tensile, compressive flexural,	Optimum infill density of 100%, infill pattern of linear, print speed of 90 mm/s, and print temperature of 215°C. CFR-PLA^d is the strongest material.	[42]
PLA	Infill density and angle of orientation	Full factorial	Tensile	100% infill density and ±45° build direction are the ones with the optimum performance.	[43]
PLA	Raster angle	DIC^e	Tensile, fracture	Anisotropic behavior in both, largest at 45°/−45° and least at 0°/90°.	[44]
PLA, ABS	Layer thickness, raster width, airgap, and part orientation	Mathematical approach (MATLAB), DOE, RSM	Geometrical deformation, surface roughness	According to mathematical analysis, among all process parameters, layer thickness and raster width have a significant effect.	[45]
PLA	Raster angle, raster width, and layer height	ANFIS^f	Tensile	Tensile strength is decreased with increment in layer height and is the highest for a raster angle of 0° and raster width of 0.6 mm.	[46]
PLA	Infill density, speed, and print temperature	RSM, CCD^g, GA-RSM, GA-ANN^h, GA-ANFIS	Tensile	Highest tensile strength achieved at the result of 100%, 124.778 mm/s, 210°C using GA-ANN with the maximum accuracy of 99.89%.	[47]
PLA	Infill density, print speed, and layer thickness	Taguchi method, S/N ratio	Tensile	Optimum parameters are infill density of 80%, print speed of 40 mm/s, and layer thickness of 0.2 mm.	[48]
PLA	Infill density, layer thickness, and extrusion temperature	Taguchi	Tensile, impact, and hardness	50%, 0.4 mm, 220°C for tensile 30%, 0.2 mm, 210°C for impact 50%, 0.3 mm, 215°C for hardness 50%, and 0.3 mm, 210°C for combinations.	[49]
PLA	Layer height, shell thickness, infill density, orientation angle, and print speed	RSM, L16 factorial	Tensile	Infill density is a principal parameter, printing speed strongly influences thermal energy, the higher the thickness, the stronger the manufacturing parts.	[50]
PLA	Layer thickness, airgap, orientation, temperature	Heat and chemical treatment	Tensile	Improvement with heat treatment is less (6%) but with chemical treatment it is high up to a 12% change.	[51]
PLA	Infill density	Full factorial	Tensile, hardness, impact, flexural	100% infill density gives the best mechanical properties.	[52]
PLA	Printing speed, infill rate, and raster angle	Taguchi	Tensile	30 mm/s of printing speed, 100% of infill rate, and 0/90° scanning angle are optimum operations determined as parameters.	[15]
CFR-PLA	Build direction, infill percentage, and layer thickness	TOPSIS^i	Tensile, izod impact	Infill percentage and layer thickness effects are significantly higher. Optimum results according to TOPSIS are: 80% infill, 0.2 mm layer thickness, and X building direction for tensile strength.	[53]
PLA	Raster angle	RSM, DIC	Tensile	Tensile strength is highest if the fibers are aligned with the loading direction and for orientation with a raster angle of 90°, the material is quite isotropic. Investigate a new layer staggering scheme with alternating layers aligned symmetrically to the loading direction, indicated by [β/−β].	[30]
PLA	Layer thickness, nozzle temperature, bed temperature, infill density	Thermal and chemical treatment	Tensile	Tensile strength when using thermal treatment did not change significantly; but in the case of chemical treatment with acetone, there was a noticeable decrease in strength.	[54]
CFR-PLA	Infill density, print speed, and layer height	Taguchi, L9 orthogonal array	Tensile	The optimum set is 80% infill density, 80 mm/s print speed, and 0.1 mm layer height.	[55]
CFR-PLA	Print orientation, bed temperature, nozzle temperature, print speed, infill density	Taguchi, L18 orthogonal array	Tensile, impact	CFR-PLA showed a rougher surface morphology than pure PLA. 45°, 60%, 70°C, 220°C, and 55 mm/s give an optimum combination of mechanical properties.	[56]
PLA	Layer thickness, infill density, print speed, temperature, and build orientation	RSM, CCD, ANN	Tensile	0.27 mm, 70%, 60 mm/s, 200°C, 45° give best tensile strength.	[16]
PLA	Infill density and print pattern	Taguchi method, L9 orthogonal array	Tensile	Hexagonal printing pattern and filling rate of 100%. The printing pattern parameter is the most influential parameter that affects the tensile strength of FDM specimens.	[57]
PLA, ABS, PETG	Infill density and infill pattern	Full factorial	Tensile	Only the infill pattern significantly influences the tensile properties. For base PLA, ABS increased by 7.5%, and PETG increased by 10% strength.	[58]
PLA	Print speed and print temperature	DIC, SEM	Tensile	The print temperature increases, the tensile strength tends to rise first and then decreases, and as the print speed increases, the tensile strength tends upward. The optimum print temperature is 230°C and the print speed is 60 mm/min.	[59]
PLA	Print orientation and layer thickness	Full factorial	Tensile	Tensile strength is highly dependent on print orientation and is the highest at 0°/90° and it increases when layer thickness decreases.	[60]
PLA	Infill density number of aluminum layer and bed temperature	Taguchi	Tensile	Tensile strength is directly proportional to infill density but inversely proportional to the number of aluminum layers. Bed temperature is insignificant.	[61]
PLA	Printing angle, layer thickness, fill rate, and nozzle temperature	RSM	Tensile	When the printing angle is less than 45°, the failure mode of the specimens is an interlayer fracture, and when its greater than 45°, the failure mode is an intra-layer fracture. Tensile strength at break decreases with decreasing fill rate and increases with the layer thickness. But tensile strength increases as nozzle temperature raises from 195°C to 210°C and rapidly decreases as nozzle temperature raises from 210°C to 230°C.	[9]
PLA	Layer height, infill percentage, and infill pattern	RSM, CCCD	Tensile	Tensile strength greatly depends on layer thickness. The optimum setting is 0.1 mm layer thickness, 100% infill density, and hexagonal infill pattern.	[62]
PLA	Layer thickness, print orientation	GRRMSE^j	Tensile failure	As layer thickness declines from 0.3 mm to 0.1 mm, the tensile failure strength increases for 45° and 60°.	[63]
PLA	Layer height, fill density, printing velocity, and orientation	Taguchi	Tensile	75% of infill density, 0° of orientation, 0.4 mm of layer height, and 40 mm/s velocities are the best combination to give better tensile strength.	[64]
PLA	Raster angle and moisture content	DOE	Tensile, strain, modulus of elasticity	The specimen with a 90° raster angle and 10% moisture content has the optimum mechanical strength and strain.	[65]
FR-PLA	Layer height, extrusion width, printing temperature, printing speed	FESEM^k	Tensile	Tensile strength gradually decreases with an increase in layer height and extrusion width.	[66]
PLA, CF-PLA	Bed temperature, extrusion temperature	SEM	Tensile, flexural, shear	On-edge and flat orientations displayed the best mechanical properties. CF-PLA has the greatest tensile and flexural strength with 47.1% and 89.75% of enhancement, respectively.	[67]
PLA	Layer thickness, infill density, and print bed temperature	RSM	Tensile, impact	It shows that an infill density of 44.7%, a layer thickness of 0.44 mm, and a bed temperature of 20°C give the optimum tensile and impact strength.	[68]

^aDifferential Scanning Calorimeter, ^bScanning Electron Microscope, ^cThermogravimetry Analysis, ^dCarbon Fiber-Reinforced Polylactic Acid, ^eDigital Image Correlation, ^fAdaptive Neuro-Fuzzy Interface System, ^gCentered Composite Design, ^hGenetic Algorithm Artificial Neural Network, ⁱThe Technique for Order of Preference by Similarity to Ideal Solution, ^jGeneralized-Relative Root-Mean-Square Error, and ^kField Emission Scanning Electron Microscopy.