Investigation of the effect of variable layer thickness on PLA parts produced with FDM 3D printer

Document Type : Research Article

Author

Kütahya Dumlupınar University, Simav Technology Faculty, Department of Mechanical Engineering

10.24200/sci.2025.65601.9573

Abstract

Fused deposition modeling (FDM) is a rapidly growing 3D printing technology. The continuously developing 3D printing technology allows parts with different structures to coexist in one part. In the study, the effects of using 0.1, 0.2, and 0.3 mm layer thicknesses determined within the same structure on tensile strength and build time were experimentally investigated. The tensile test sample thickness (3.6 mm) was divided into three sheets with different layer thicknesses, and the effect of the ratio of the inner sheet thickness (1.2 mm, 1.8 mm, and 2.4 mm) to the sample thickness (33.33%, 50%, and 66.66%) was also evaluated. The experimental results were also analyzed using the Pareto front multi-objective optimization method. While the lowest tensile strengths were obtained in samples where 0.2 mm and 0.3 mm layer thicknesses were used together, the highest tensile strengths were obtained in samples where 0.1 mm layer thickness was used together with 0.2 mm and 0.3 mm layers. Considering the build times of samples with fixed and variable layer thicknesses without compromising on strength, approximately 20% savings were achieved in the build times of samples with variable layer thicknesses. However, when tensile strength and production time are optimized, optimum results for the most balanced solution were obtained using 0.3 mm outer sheet layer thicknesses and 0.1 mm inner sheet layer thicknesses together. This situation also directly affects production costs. As a result of the study, it was determined that variable layer thickness is significant in terms of both strength and build time.

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Articles in Press, Accepted Manuscript
Available Online from 09 June 2025
  • Receive Date: 26 October 2024
  • Revise Date: 05 May 2025
  • Accept Date: 09 June 2025