Parametric analysis of processing variables for enhanced adhesion in metal-polymer composites fabricated by fused deposition modeling

Fused deposition modeling (FDM) is a popular additive manufacturing technique, but attaining optimal processing variables continues to be a significant challenge. The design of experiments (DOE) method is used in this work to explore the effect of processing factors on the mechanical characteristics of metal-polymer composites generated by FDM, with a particular focus on adhesion. Filling quantity, extruded temperatures, raster orientation, and film thickness are considered fundamental design factors in the study, which employs Taguchi optimization methodology and Analysis of Variance (ANOVA) to investigate the relationship between processing variables, and tensile characteristics, such as ultimate tensile strength, yield strength, Young’s modulus, ductility, and elongation at fracture. Tensile strength improved by 57% and yield strength increased by 85% when 20% aluminium was added to polylactic acid (PLA). It was also discovered that the ductility decreased with each incremental addition of aluminium to PLA. The tension investigation tests were carried out in line with ASTM D638-10. The results suggest that optimizing processing factors, such as 100% filling amount, 220 °C extruded temperature, 90° raster orientation, and 0.1 mm film thickness may greatly improve adhesion in FDM-fabricated metal-polymer composites.