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Feasibility of Direct 3D Printing Foam Polylactic Acid with MEX

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Abstract:

Additive manufacturing of polymeric foams via Material Extrusion (MEX) is an attractive route to lightweight components with tunable mechanical response. However, reproducible performance remains challenging because foam expansion, cell stabilization, and inter-layer bonding are strongly governed by the thermal–processing window. This study evaluates the feasibility of directly printing a commercial PLA foaming filament and quantifies the influence of nozzle temperature (and the associated flow-rate adjustment) on density and tensile behavior. ISO 527-2 tensile specimens were printed under three printing-condition combinations, a nominal PLA setting (190°C, 100% flow) and two foaming-window settings (250°C, 55% flow and 270°C, 50% flow). Tensile tests were conducted, and the tensile properties were assessed via Young’s Modulus, Yield and Ultimate properties (stress/strain), and elastic and total absorbed energy up to fracture. In addition to absolute values, all relevant metrics were normalized by relative density to enable robust comparisons across foaming levels. Finally, the DIC maps at the Yield and Fracture point were used to support the derived results and conclusions.

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Info:

Periodical:

Key Engineering Materials (Volume 1047)

Pages:

223-230

Online since:

April 2026

Authors:

Batagiannis Athanasios, Panagiotis Karmiris-Obratański, Ioannis T. Christodoulou, Emmanouil Lazaros Papazoglou, Angelos P. Markopoulos*

Keywords:

Different Temperatures – Flow Rates, Material Extrusion, PLA - Foam PLA, Tensile Properties

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Creative Commons CC BY 4.0

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* - Corresponding Author

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