Investigation of the mechanical properties and porosity relationships in fused deposition modelling‐fabricated porous structures

Purpose The purpose of this paper is to investigate the mechanical properties and porosity relationships in fused deposition modelling (FDM) fabricated porous structures. Design/methodology/approach Porous structures of numerous build architectures aimed at tissue engineering (TE) application were fabricated using the FDM. The employment of FDM to fabricate these non‐random constructs offers many advantages over conventional scaffold fabrication techniques as patient specific scaffolds with well‐defined architectures and controllable pore sizes can be fabricated accurately and rapidly. There exist several FDM parameters that one needs to specify during the scaffold fabrication process. These parameters, which can be interdependent and exhibit varying effects on scaffold properties, were identified and examined using the design of experiment (DOE) approach. Essentially, the effects of five FDM process parameters, namely air gap, raster width, build orientation, build layer and build profile, on the porosity and mechanical properties of acrylonitrile‐butadienene‐styrene (ABS) scaffold structures with three‐dimensional interconnectivity were investigated in two designed experiments. Statistical analyses of the data were performed and the respective factors that have significant influence on the porosity and mechanical properties of the scaffolds were identified. The relationship between scaffold's mechanical properties and porosity was thereafter established empirically. Findings Models of TE scaffolds of numerous build architectures were successfully fabricated using different parameter settings on the FDM. The DOE approach determined air gap and raster width as the most significant parameters in affecting the porosity and mechanical properties of the ABS scaffold structures. The relationship between scaffolds' mechanical properties and porosity was determined to be logarithmic, with the best mechanical properties observed in scaffolds of low porosity. Originality/value The paper highlights how the application FDM to tissue scaffold application can overcome most of the limitations encountered in the conventional techniques.