Design of Experiments Methodology for Fused Filament Fabrication of Silicon-Carbide-Particulate-Reinforced Polylactic Acid Composites

Fused Filament Fabrication (FFF) is an additive manufacturing technique that constructs parts by extruding material layer by layer. It offers advantages such as rapid prototyping, cost-effectiveness, and the ability to produce complex geometries. This study investigates the mechanical behavior of a composite filament composed of silicon carbide (SiC) ceramic particulates embedded in a polylactic acid (PLA) matrix, fabricated via FFF. Pure PLA specimens were also printed and tested to serve as a baseline. A Design of Experiments (DOE) methodology was employed to evaluate the influence of key printing parameters on mechanical properties, including Young’s modulus, yield strength, and ultimate strength. Microstructural analysis was performed on printed specimens using scanning electron microscopy (SEM). For compression testing, the parameters studied were infill percentage, number of shells, and print orientation. For tensile testing, the parameters included layer height, number of shells, and infill angle. Results indicated that infill percentage had the most significant impact on compressive properties, while layer height was the dominant factor in tensile performance. These findings provide insights into optimizing FFF process parameters for ceramic-particulate-reinforced polymer composites.