Optimization of Fused Deposition Modeling (FDM) Parameters Towards Dimensional Accuracy of Polylactic Acid (PLA) Stent

Abstract:

The demand for coronary artery stents has risen due to global healthcare advancements. However, conventional fabrication methods often fail to meet clinical standards for dimensional accuracy and efficiency. This study aims to determine optimal 3D printing parameters for high precision polylactic acid (PLA) stents using fused deposition modeling (FDM). Twenty-six parameter combinations were designed via response surface methodology (RSM), varying printing speed (4–8 mm/s), nozzle temperature (190–220°C), orientation (XY, ZY), and layer thickness (0.05–0.2 mm). Optical microscopy was used to assess dimensional accuracy against computer-aided design (CAD) models. Only six combinations successfully printed stents, and four were further optimized. The best-performing sample showed a length deviation of 1.21% and a width deviation of 33%. Results confirm that printing speed critically affects dimensional precision. The study concludes that optimal FDM settings are material-specific; for PLA, the best range was 3–4 mm/s speed, 190–220°C nozzle temperature, ZY orientation, and 0.1–0.2 mm layer thickness. These findings support the feasibility of using FDM to fabricate dimensionally accurate PLA stents for coronary applications.

• Periodical: Key Engineering Materials (Volume 1027)
• Pages: 27-34
• DOI: https://doi.org/10.4028/p-itpO6G
• Online since: October 2025
• Authors: Kuang Yee Ng*, Noorhafiza Muhammad, Mohd Shuhidan Saleh, Nazirul Mubin Ab. Aziz, Mohd Haidiezul Jamal b. Ab Hadi, Muhammad Nur Amalina, V.K. Bupesh Raja, Kamalakanta Muduli
• Keywords: 3D Printing, Coronary Artery Stents, Dimensional Accuracy, Fused Deposition Modeling (FDM), Polylactic Acid (PLA)

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