Investigation of FDM-Based 3D Printing of PLA–Copper Composites for Enhanced Product Quality

Abstract:

Fused Deposition Modeling (FDM) is used primarily to fabricate parts with complex geometries, but dimensional inaccuracies can often result in inefficiencies and limits to its use in high-precision applications. This problem increases in metal–polymer composites, such as this PLA–copper study, because of the combination due to the incorrect dimensional reactions of the heterogeneous materials. Thus, enhancing dimensional accuracy is critical in this application, not only to disprove the need for post-processing but also to support industrial applications. This investigation evaluates the impact of layer thickness, print speed, infill density, and wall thickness on the dimensional accuracy of PLA–copper parts. The experimental design using Taguchi’s L9 orthogonal array created 9 unique parts to evaluate and measure deviations in geometrical properties. Analysis of the results indicated that wall thickness exhibited the greatest influence on length accuracy, while layer thickness predominated breadth accuracy. For square side length and diameter accuracy, layer thickness and infill density appeared to have the most influence, respectively.

• Periodical: Advanced Materials Research (Volume 1189)
• Pages: 17-29
• DOI: https://doi.org/10.4028/p-a6zT0w
• Online since: March 2026
• Authors: Sanraj S. Bagadi*, Sunil J. Raykar, Pankaj B. Nandgave, Rahul R. Patil, Tanish A. Barad
• Keywords: 3D Printing, Additive Manufacturing, Dimensional Accuracy, FDM, PLA-Copper Composite

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