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Hybrid Layer Thickness Configurations for Enhanced Mechanical Performance and Energy Efficiency FDM-Printed PLA

Year 2025, Volume: 9 Issue: 2, 279 - 294

Mesut Uysal

Abstract

This study examines the impact of hybrid layer thickness configurations on the mechanical properties and energy consumption of 3D-printed polylactic acid (PLA) parts produced via Fused Deposition Modeling (FDM). PLA specimens with various combinations of outer and core layer thicknesses (0.08 mm, 0.16 mm, and 0.28 mm) were fabricated and tested for tensile strength, flexural strength, and flexural modulus, alongside measurements of energy consumption. The results revealed that hybrid structures incorporating 0.16 mm face layers and 0.08 mm core layers exhibited superior mechanical performance. In contrast, thicker core layers (0.28 mm) significantly reduced printing time and energy use. The highest tensile strength (53.57 MPa), flexural strength (90.68 MPa), and flexural modulus (2898.4 MPa) were obtained in the sample group of 0.16_0.08_0.16 mm layer thickness. Scanning Electron Microscopy (SEM) provided microstructural insights supporting these findings. The porosity and higher nozzle temperature may influence the material strength for thicker and thinner layer thicknesses, respectively. The sample group with the least energy consumption was 0.28 mm, followed by the sample group with the same layer thickness in both the face and core layers. The study highlights the potential of hybrid layering strategies to optimize performance-energy trade-offs in FDM printing, offering valuable guidance for material-efficient and functionally robust additive manufacturing.

Keywords

3D printing Layer thickness Flexural properties Tensile strength Energy consumption

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There are 27 citations in total.

Details

Primary Language English
Subjects Polymers and Plastics, Forest Industry Engineering (Other)
Journal Section Research Articles
Authors

Mesut Uysal 0000-0003-0114-3030

Early Pub Date October 28, 2025
Publication Date October 28, 2025
Submission Date June 9, 2025
Acceptance Date September 1, 2025
Published in Issue Year 2025 Volume: 9 Issue: 2

Cite

APA Uysal, M. (2025). Hybrid Layer Thickness Configurations for Enhanced Mechanical Performance and Energy Efficiency FDM-Printed PLA. Journal of Innovative Science and Engineering, 9(2), 279-294. https://doi.org/10.38088/jise.1716224
AMA Uysal M. Hybrid Layer Thickness Configurations for Enhanced Mechanical Performance and Energy Efficiency FDM-Printed PLA. JISE. October 2025;9(2):279-294. doi:10.38088/jise.1716224
Chicago Uysal, Mesut. “Hybrid Layer Thickness Configurations for Enhanced Mechanical Performance and Energy Efficiency FDM-Printed PLA”. Journal of Innovative Science and Engineering 9, no. 2 (October 2025): 279-94. https://doi.org/10.38088/jise.1716224.
EndNote Uysal M (October 1, 2025) Hybrid Layer Thickness Configurations for Enhanced Mechanical Performance and Energy Efficiency FDM-Printed PLA. Journal of Innovative Science and Engineering 9 2 279–294.
IEEE M. Uysal, “Hybrid Layer Thickness Configurations for Enhanced Mechanical Performance and Energy Efficiency FDM-Printed PLA”, JISE, vol. 9, no. 2, pp. 279–294, 2025, doi: 10.38088/jise.1716224.
ISNAD Uysal, Mesut. “Hybrid Layer Thickness Configurations for Enhanced Mechanical Performance and Energy Efficiency FDM-Printed PLA”. Journal of Innovative Science and Engineering 9/2 (October2025), 279-294. https://doi.org/10.38088/jise.1716224.
JAMA Uysal M. Hybrid Layer Thickness Configurations for Enhanced Mechanical Performance and Energy Efficiency FDM-Printed PLA. JISE. 2025;9:279–294.
MLA Uysal, Mesut. “Hybrid Layer Thickness Configurations for Enhanced Mechanical Performance and Energy Efficiency FDM-Printed PLA”. Journal of Innovative Science and Engineering, vol. 9, no. 2, 2025, pp. 279-94, doi:10.38088/jise.1716224.
Vancouver Uysal M. Hybrid Layer Thickness Configurations for Enhanced Mechanical Performance and Energy Efficiency FDM-Printed PLA. JISE. 2025;9(2):279-94.
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