Effect of FDM 3D Printing Process Parameters on Polylactic Acid in Impact Testing for Medical Implants

Abstract:

Polylactic acid (PLA) has become a promising material for medical implants due to its biocompatibility, biodegradability, and favorable mechanical properties. With advancements in Fused Deposition Modeling (FDM) 3D printing technology, it is possible to further optimize the performance of PLA by adjusting printing parameters. This optimization is crucial for enhancing the energy absorption and durability of PLA, especially in applications like medical implants that require reliable mechanical strength. This study utilized Response Surface Methodology (RSM) with the Box-Behnken Design (BBD) to investigate the effects of key FDM 3D printing parameters—layer thickness, infill pattern, and infill density—on the energy absorption and durability of PLA. A total of 15 experiments were conducted, with each factor tested at three levels. The standard Charpy impact test (ISO 179) was used to measure energy absorption in samples of dimensions 80x10x4 mm. This research aims to identify the key FDM 3D printing parameters that maximize the energy absorption and durability of polylactic acid (PLA) for use in medical implants, leveraging PLA's biocompatibility and mechanical properties. The study found that infill density and infill pattern are the two most critical factors affecting the energy absorption and durability of PLA. An infill density of 80% was determined to be optimal, as higher densities significantly improved energy absorption. Additionally, the grid infill pattern, combined with the highest layer thickness of 0.3 mm, provided the best performance. In conclusion, these findings offer valuable insights for optimizing PLA in medical implant applications, with potential for further refinement based on specific use cases.

• Periodical: Nano Hybrids and Composites (Volume 47)
• Pages: 17-29
• DOI: https://doi.org/10.4028/p-eO2CfT
• Online since: October 2025
• Authors: Reem S. Khzaall*, Wisam K. Hamdan, Marwan N. Arbilei
• Keywords: 3D Printer, Analysis of Variance, Box Behnken Design (BBD), Charpy Impact Test, Polylactic Acid (PLA)

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