Parametric optimization of intra‐ and inter‐layer strengths in parts produced by extrusion‐based additive manufacturing of poly(lactic acid)

ABSTRACT Parts produced by extrusion‐based additive manufacturing experience the disadvantage of consisting of many weld‐lines, which consequently downgrade their mechanical properties. This work aims at maximizing the strength of printed parts by considering and improving the intra‐ and inter‐layer cohesion between adjacent strands. Therefore, printed poly(lactic acid) specimens were characterized by means of a particular tensile test setup, and the inter‐layer cohesion of printed specimens was evaluated by means of the double cantilever beam test. A detailed parametric statistical evaluation, which included printing temperatures, layer thicknesses, and layer‐designs, was complemented by the material's viscosity data and the analysis of the specimens' fracture surfaces and cross‐sections. An optimal layer‐design was found to be a key parameter in the optimization of strength with regard to different loading directions. Additionally, the maximization of the cohesion leads to a tremendous improvement in the mechanical performance of the printed parts, resulting in strengths of roughly 90% of those of compression‐molded parts. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134 , 45401.