Analysing the effects of layer heights and line widths on FFF-printed thermoplastics

One of the most used additive manufacturing methods in the market is fused filament fabrication (FFF) due to its affordability and ease of operation. However, identification of optimal processing parameters is still a challenge and can help to achieve desired results in parts made by FFF. This paper presents the influence of two process parameters, i.e. layer height and line width on FFF-printed thermoplastics. Premium PLA, Haydale’s Synergy Graphene Enhanced Super Tough PLA, ABS Extrafill and ASA Extrafill have been manufactured and tested according to British and International standards for this study. An extensive comparative analysis has been provided where parts have been manufactured using Anet® ET4 Pro 3D printer with the four materials at five different line widths (0.2 mm, 0.4 mm, 0.6 mm, 0.8 mm, 1 mm) and four different layer heights (0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm). The study analyses the effects of line widths and layer heights on mass, dimensional accuracy, surface texture and mechanical properties of the four materials. Microstructural analysis has also been carried out to evaluate the fractured surfaces and to determine the impact of modifying the two processing parameters on failure modes. Results have shown the trade-offs that can be made with the different materials in terms of properties and manufacturing time by modifying the layer heights and line widths. Designers and manufacturers can use this comparative analysis amongst the four materials to identify the limitations with the default printing settings (0.2 mm layer height and 0.4 mm line width) on most 3D printers and achieve desired results by leveraging the layer heights and line widths.