Investigation on Composite Sandwich PLA printed parts and Control Parameter optimization

Although additive manufacturing is widely used in all industries, its applications are limited due to poor mechanical properties. Current research focuses on improving the strength of 3D printed composites by changing control parameters (raster angle, layer thickness, and shell count), and developing the new composite and sandwich composite through the Fusion Deposition Modelling (FDM) printing process. The parameters influencing the tensile strength of the printed part, such as raster angle, layer thickness, and the number of shells, are considered at three levels and discussed in the research. According to the investigation’s findings, the tensile strength can be significantly (up to 12.7%) increased by adjusting the control parameters (in order of the number of shells, layer thickness, and fill orientation) and significantly improved by using the sandwich construction. When printing with different controllable parameters, it has been discovered that the fewer the outer shells give, the greater the tensile strength. Fractography analysis was performed to identify the fracture type, and scanning electron microscopic analysis was performed to identify the layer’s inner failure analysis. Finally, it was discovered that there was a close relationship between the number of outer shells and the thickness of the layers. The excellent tensile strength improvement in PLA-composite sandwiches was also discovered. Overall, the PLA/Ceramic sandwich 3D printed parts showed the maximum tensile strength over the PLA, composites, and other sandwiches and tested for 3D printed hangers.