Optimizing Fused Deposition Modeling (FDM) Parameters to Improve the Impact Resistance of Nano Calcium Carbonate-Coated Polylactic Acid (PLA) Components

This investigation focuses on determining the optimal process variables to achieve maximum impact strength in Polylactic Acid (PLA) parts uniformly coated with Nano Calcium Carbonate (CaCO₃) produced via fused deposition modeling (FDM). Enhancing impact strength is critical for improving the functional performance of PLA products across various applications. The study utilized the Taguchi L9 orthogonal array methodology to evaluate the effects of layer thickness, printing orientation, and heat treatment on impact strength, as measured by the Izod impact test. Results indicated that the highest impact strength of 590.25 J/m was attained using a 0.08 mm layer thickness, upright orientation, 50°C heat treatment, and a 75 degree bending angle. The Nano calcium carbonate coating consistently enhanced impact strength across all parameter combinations, with printing orientation identified as the most significant factor influencing the results. Even with a 0.08mm layer thickness and heat treatment at peak resulted in lower impact strength compared to the optimized upright orientation. This study underscores the importance of optimizing FDM process parameters alongside the application of Nano calcium carbonate coatings to achieve superior mechanical properties in 3D printed PLA components. The insights gained from this research provide a pathway for developing durable and high performance PLA based materials, suitable for load bearing and impact resilient applications in engineering and consumer products.