Experimental Investigation into the Influence of Infill Density, Print Pattern, and Built-Up Direction on the Flexural Strength of FFF-Manufactured PLA Components
Abstract
1. Introduction
2. Materials and Methods
2.1. Experimental Setup
2.2. Material, Sample Geometry, and Printing Orientation
2.3. Printing and Slicing Settings
| Printer | Prusa Mini (Firmware 6.4.0-RC2+11973) |
| Slicer | Prusa Slicer Ver. 2.9.4 |
| Filament Manufacturer | Polymaker (Changshu, China) |
| Filament Material | PLA (PolyTerra) |
| Filament Diameter | 1.75 mm |
| Filament Color | Charcoal Black |
| Bed Temperature | 60 °C |
| Nozzle Temperature | 215 °C (230 °C for first layer) |
| Nozzle Diameter | 0.4 mm |
| Layer Heigth | 0.2 mm |
| Extrusion Multiplier | 1 |
| Printing Speed (Infill) | 115 mm/s |
| Printing Speed (Perimeter) | 45 mm/s |
| Perimeters | 2 |
3. Results
3.1. Flexural Strength
3.2. Printing Time
3.3. Failure Methods
3.3.1. Deformation Exceeded


3.3.2. Delamination of Outer Wall
3.3.3. Failure of Layer Adhesion
4. Discussion
4.1. Influence of Built-Up Direction
4.2. Infill Density and the Transition from Infill- to Skin-Dominated Behavior
4.3. Effect of Infill Pattern and Orientation Dependence
4.4. Strength-to-Print-Time Efficiency and Fatigue Considerations
4.5. Generalization Across Materials and Structural Reinforcement
5. Conclusions
- Printing in the Y-direction with a cubic pattern and infill densities above 60% provides an optimal compromise between flexural strength and production efficiency. With an infill level of 90%, the highest flexural strength value of just under 31 MPa was achieved for comparatively short printing times.
- Both X-printed patterns also displayed high performance at low infill densities. Up to an infill density of approx. 60%, the strength values for both infill patterns are even higher than those for the Y-C configuration. However, comparatively long printing times are a negative factor here.
- In general, it was possible to demonstrate the well-known fact that strength values increase with increasing infill density. Interestingly, this does not entirely apply to samples printed in the Z-direction in the present study. Here, the flexural strength at an infill density of 90% is at the same level (cubic) or even below (triangular) 70%.
- For samples printed in X- and Y-directions, the cubic pattern leads to increased flexural strength compared to the triangular pattern within the built-up direction, whereas for the Z-direction, the triangular pattern yielded higher values across all infill densities considered.
- Flexural strength for X- and Z-directions increase equally for both filling patterns as the infill density increases, whereas for samples in the Y-direction, flexural strength for the cubic pattern increases more strongly than for the triangular pattern.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
Abbreviations
| AM | Additive Manufacturing |
| ABS | Acrylnitril-Butadien-Styrol |
| DIC | Digital Image Correlation |
| FFF | Fused Filament Fabrication |
| MEX | Material extrusion |
| PETG | Poly Ethylene Terephthalate Glycol |
| PLA | Poly Lactic Acid |
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| Length l | Width b | Height h |
|---|---|---|
| Flexural Strength (MPa) | |||||
|---|---|---|---|---|---|
| Infill Density | 10% | 30% | 50% | 70% | 90% |
| X-Triangle | 19.33 ± 0.27 | 21.96 ± 0.74 | 25.36 ± 0.45 | 25.92 ± 0.77 | 27.21 ± 0.39 |
| X-Cubic | 22.60 ± 1.49 | 25.06 ± 1.33 | 28.12 ± 0.62 | 28.10 ± 1.10 | 30.71 ± 1.14 |
| Y-Triangle | 14.43 ± 0.74 | 17.23 ± 0.39 | 18.87 ± 0.56 | 20.61 ± 0.21 | 21.98 ± 0.46 |
| Y-Cubic | 17.02 ± 0.53 | 20.41 ± 0.27 | 23.41 ± 0.31 | 26.59 ± 0.26 | 30.73 ± 0.13 |
| Z-Triangle | 12.41 ± 1.42 | 12.17 ± 1.95 | 14.34 ± 1.60 | 16.66 ± 2.23 | 15.52 ± 1.47 |
| Z-Cubic | 10.01 ± 1.37 | 10.83 ± 0.21 | 11.12 ± 2.23 | 13.20 ± 1.30 | 12.87 ± 1.37 |
| Infill Density | 100% | ||||
| X-Rectilinear | 43.46 ± 2.98 | ||||
| Y-Rectilinear | 37.15 ± 0.83 | ||||
| Z-Rectilinear | 22.57 ± 2.47 | ||||
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Buss, C.; Reci, F.; Hribernig, T.; Steininger, S. Experimental Investigation into the Influence of Infill Density, Print Pattern, and Built-Up Direction on the Flexural Strength of FFF-Manufactured PLA Components. J. Manuf. Mater. Process. 2026, 10, 21. https://doi.org/10.3390/jmmp10010021
Buss C, Reci F, Hribernig T, Steininger S. Experimental Investigation into the Influence of Infill Density, Print Pattern, and Built-Up Direction on the Flexural Strength of FFF-Manufactured PLA Components. Journal of Manufacturing and Materials Processing. 2026; 10(1):21. https://doi.org/10.3390/jmmp10010021
Chicago/Turabian StyleBuss, Christoph, Fabio Reci, Thomas Hribernig, and Stefan Steininger. 2026. "Experimental Investigation into the Influence of Infill Density, Print Pattern, and Built-Up Direction on the Flexural Strength of FFF-Manufactured PLA Components" Journal of Manufacturing and Materials Processing 10, no. 1: 21. https://doi.org/10.3390/jmmp10010021
APA StyleBuss, C., Reci, F., Hribernig, T., & Steininger, S. (2026). Experimental Investigation into the Influence of Infill Density, Print Pattern, and Built-Up Direction on the Flexural Strength of FFF-Manufactured PLA Components. Journal of Manufacturing and Materials Processing, 10(1), 21. https://doi.org/10.3390/jmmp10010021

