Optimization of Fused Deposition Modeling Parameters for Enhanced Tensile Performance of PLA Using Taguchi and ANOVA Approaches

Fused Deposition Modeling (FDM) is one of the most widely adopted additive manufacturing techniques, where the performance of printed parts strongly depends on structural parameters governing polymer filament deposition. This study investigates the influence of infill pattern, wall line count, and top/bottom layers on the tensile properties of PLA. A Taguchi experimental design combined with ANOVA was applied to evaluate parameter significance. The optimal configurations were: a cubic subdivision pattern with six wall lines and four top/bottom layers yielding a Young’s modulus of 3998.3 MPa; a triangular pattern with six wall lines and six top/bottom layers achieving a tensile strength of 53.26 MPa; and a grid pattern with four wall lines and six top/bottom layers resulting in a Poisson’s ratio of 0.236. ANOVA results indicated that top/bottom layers had the strongest influence on Young’s modulus and tensile strength, while infill pattern was the dominant factor affecting Poisson’s ratio and stiffness-to-weight ratio. These findings highlight the critical role of structural parameters in optimizing mechanical performance without increasing infill density, enabling lightweight yet high-strength PLA structures.These findings highlight the critical role of parameter interactions in mechanical optimization, confirming that mechanical performance can be significantly enhanced without increasing infill density, thereby enabling lightweight yet high-strength structures.