An experimental investigation on 3d printing of PETG-KF-based composites: optimization of process parameters for improved mechanical properties

In the field of additive manufacturing, Fused Filament Fabrication (FFF) is a prominent techniques used to create elaborate three-dimensional objects without wasting materials. 3D-printing technology has been revolutionized with the polymer Polyethylene Terephthalate Glycol (PETG), replacing traditional polymers because of its chemical toughness and mechanical strength. In addition, composites made of PETG, especially those reinforced with fibers, have proven their versatility in different fields. However, the key issue is to prepare PETG composites with optimal mechanical performance throughout their service life, which requires precise fine-tuning of printing parameters. Therefore, this study attempted to optimize several process parameters, including orientation, print speed, layer height, and infill density, to achieve the full potential of printed aramid-fiber-reinforced PETG (PETG-KF) composites. The specimens were manufactured carefully according to the L16 orthogonal array, which ensured full variation of the parameters using Taguchi optimization. Following this, a comprehensive Analysis of Variance was performed with a 95% confidence interval as a support, which allowed for a comprehensive evaluation of the effects of the printing parameters on the bending properties. Based on the results, the optimal performance in bending properties of PETG-KF materials was achieved at a printing speed of 80 mm/s, 0.20 mm layer height, and 100% infill-density. This study not only elucidates the complex process of optimizing 3D-printing parameters but also offers valuable insights into improving the mechanical properties of PETG-KF-based composites. In addition, the investigation covers various mechanical attributes, including Ultimate Tensile Strength, hardness, fatigue resistance, and impact strength, which show significant improvement in 3D-printing.